easyarc opman

10. FlexArc U/L

EasyArc Operation Manual

2017507

ABB Flexible Automation

FlexArc U2/L CellEasyArc Operation ManualDocumentation Key2018537

Section Title

Ea2_2_17 Software description FlexArc U2/LEa2_3_3 Cell Setup - dual station w/parkEa2_4-1 Main menu - All cellsEa2_4-2_1 Setup menu - no indexEa2_4-3_3 Test Menu - dual stationEa2_4-4_6 Manual Operations - dual L cellEa2_4-5_3 Production Menu - dual stationEa2_4-6_3 Information Menu - dual stationEa2_4-7_3 Operation - single station w/park

Earc_5_0 Adding a weld program

Earc_6_3 Adding an error handler

Append6_2 Error handling instructions

Cov_14 FlexArc U2/L Cover page

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Figure 2-2 EasyArc Menu Structure

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1. EasyArc Software

EasyArc 2 is compatible with BaseWare OS 3.0 and higher versions of the S4Crobot controller software.

2. Loading EasyArc

EasyArc can be loaded from the floppy disk with the following procedure. Thedisk should first be inserted into the floppy disk drive.

2.1 From the teach pendant select FILE then OPEN. Select the program file:EasyArc.prg. EasyArc.prg contains the following software modules:

EasyArc - this module contains the routine “main”, routines for handling thefive main EasyArc menus, and generic routines for displaying menus and listson the teach pendant.

Data - this module contains declarations for the standard tool tWeldGun, astandard work object obSTN1 and the constant string stCOMPANY_NAME,which appears when the EasyArc greeting is displayed.

SL_Cell - the SL_Cell module contains the cell control logic for a single L-style positioner.

WeldPrg1 - contains the user-created weld routines for the weld table (SeeChapter 5 Adding Weld Routines)

EasyArc will contain one of the following tool modules depending on yoursystem configuration:

MIG - the mig module contains manual operation routines and error handlersfor a standard mig welding system.

MIG_AWC - the Mig_Awc module contains manual operation routines anderror handlers for an AWC (Advanced Weld Control) based welding system.

MIG_A - the Mig_A module contains manual operation routines and errorhandlers for an Arcitec based welding system.

See Section 4.4.3 Manual Operations: Tool and Chapter 6 Adding an ErrorHandler

If your system is equipped with a torch cleaner, EasyArc will contain a torchcleaner module:

TC97 – the TC97 module contains torch clean routines and data.

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2.2 Load the option modules that you need:

1. If your system is equipped with a BullsEye, after loading EasyArc.prg, thesystem will report an error:

Figure 2-1 Reference Error

Ignore this error and press OK. Press FILE then OPEN, and select thesystem module BULLSEYE.sys. Press OK.

2. If your system is equipped with a Smartac - load the system moduleSMARTAC from the floppy disk.

2.3 Figure 2-2 shows the EasyArc Menu structure.

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3. EasyArc Setup

Once you have loaded the software from the floppy disk, you can proceed tosetup the cell.

3.1 Cell Setup

The setup for the cell will proceed as follows. Run the program from Main inTEACH mode.

3.1.1 When the program is run, the greeting message will be displayed:

Figure 3.1-1 Greeting

Press PROCEED to continue. After 5 seconds this display will automaticallybe erased, and the next screen will appear.

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3.1.2 The program will display a message that informs you that the cell hasnot been setup yet:

Figure 3.1-2 Cell Not Setup Screen

Press PROCEED to continue. Once you have setup the cell, this display willnot appear again.

3.1.3 The program will then display the Cell Setup Menu.

Figure 3-3 Cell Setup Menu

The operator must set up the Safe and Service positions before anyprograms can be run. If the operator presses the CLOSE function key beforesetting the Safe and Service positions, EasyArc will display the message:

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Figure 3-4 Cell Definition Screen

The operator presses OK to exit this display and return to the Cell SetupMenu.

3.1.4 If the operator selects the Safe position menu item by pressing thefunction key 1, the program will display a message that explains how to setupthe safe position for the cell:

Figure 3-5 Safe Position Setup Screen

If you do not want to define the SAFE position, press CANCEL. If you pressOK, the program will stop. Manually jog the robot to a SAFE position. Whenthis is done, press START on the pendant to run the program again.

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The program will ask if this is the safe position:

Figure 3-6 Safe Position? Screen

Press YES. The program will display: "SAFE is now defined." If this is not thesafe position, stop the program, jog the robot to the desired safe position andstart the program again.

The program will display the Cell Setup Menu again (See Figure 3-3).

3.1.5 If the operator selects the Service position menu item by pressing thefunction key 2, the program will display a message that explains how to setupthe service position for the cell:

Figure 3-7 Service Position Setup Display

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If you do not want to define the SERVICE position, press CANCEL. If youpress OK, the program will stop. Manually jog the robot to a safe position.Jog the robot to the position in the cell were you will service the weld torch,for example by a maintenance gate. When this is done, press START on thependant to run the program again. The program will ask if this is theSERVICE position:

Figure 3-8 SERVICE Position? Screen

Press YES. The program will display the message: SERVICE is now defined.

The program will display the Cell Setup Menu again (Figure 3-3).

3.1.6 EasyArc has an optional PARK position available for use if the cell isequipped with a park switch. When the Park position is activated and defined,the robot will move to the SAFE position and then to the PARK position whenit finishes running a program. As long as the robot is in the PARK position(the Park switch is activated), the operator can enter the cell and load andunload parts.

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If the operator selects the Park position menu item by pressing the functionkey 3, if the position has not been setup yet, the program will display theActivate Park Position Menu:

Figure 3-9 Activate Park Position Menu

If the operator chooses to activate the Park position by pressing 1, thefollowing message will be displayed:

Figure 3-10 Activate Park Position Display

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If the operator presses OK, a Park position setup menu will be displayed:

Figure 3-11 Cell Setup: Park Position Menu

If the operator presses 1, the program will display a message that explainshow to setup the PARK position for the cell:

Figure 3-12 Park point Setup Display

If you do not want to define the PARK position, press CANCEL. If you pressOK, the program will stop. Jog the robot to a position where the Park switch ismade. When this is done, press START on the pendant to run the programagain.

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The program will ask if this is the PARK position:

Figure 3-13 PARK position? Display

If this is not the PARK position, stop the program, jog the robot to the desiredPARK position and start the program again.

If the robot is in the PARK position, press YES. The program will display:“PARK is now defined,” then the Cell Setup: Park Position Menu will bedisplayed again (See Figure 3-11).

If the operator selects the Deactivate Park position menu item by pressing2, the following message will be displayed:

Figure 3-14 Deactivate Park Position Display

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If the operator presses OK, the Park position option will be disabled and theActivate Park Position menu (See Figure 3-9) will be displayed again. If theoperator presses CLOSE, the program will then display the Cell Setup Menuagain (See Figure 3-3).

3.1.7 If the operator selects the Cell speeds position by pressing the functionkey 4, the program will display the robot speed setup screen and the currentrobot speed for movements to/from the safe, service and other cell positions:

Figure 3-15 Robot Speed Setup Display

To change the robot speed, press OK. The program will display the RobotSpeed entry screen:

Figure 3-16 Robot Speed Entry Display

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You must enter a value from the pendant keyboard and press OK. If you justpress OK without entering a number, the speed will be set to the minimumvalue. If the value is over the maximum, the speed will be set to the maximumvalue.

The program will display the Cell Setup Menu again (Figure 3-3).

The operator presses CLOSE to exit the CELL SETUP menu.

3.1.8 The program will then check to see if the robot is at the Safe position. Ifthe robot is not at the SAFE position, the program will ask if it is OK to moveto the cell SAFE position:

Figure 3-17 Move to Safe Prompt

If you press YES, the robot will make a joint move to the safe position. If youpress NO, the program will stop. You can then manually jog the robot to apoint where the robot can move safely to the cell safe position. When this isdone, press START to start the program. Now answer YES, and the robot willmove to the SAFE position.

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3.1.9 The Main Menu will now be displayed on the teach pendant:

Figure 3-18 Main Menu

3.1.10 Press STOP to stop the program, and save the program at this pointby selecting File and then 3 Save Program.

Figure 3-19 Save Program

This will save all the setup items and the cell module in the file EasyArc.prgon the floppy disk.

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4. Operations

The operation of the EasyArc software is described in the following section.Refer to Figure 2-2 for the structure of the EasyArc menu system.

4.1 Main Menu

When EasyArc is started from Main, first the Greeting message will bedisplayed:

Figure 4.1-1 Greeting

If the operator presses PROCEED or after 5 seconds, the Greeting will beerased and if the robot is close to the Safe position in the current station, itwill move to the Safe position.

If the robot is not close to the Safe position, EasyArc will ask if it is OK tomove to the Safe position in the current station:

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Figure 4.1-2 Move to Safe Prompt

If you press YES, the robot will make a joint move to the SAFE position. Ifyou press NO, the program will stop. You can then manually jog the robot toa point where the robot can move safely to the cell SAFE position. When thisis done, press START to start the program. Now answer YES, and the robotwill move to the SAFE position. EasyArc will then display the Main Menu.

The Main Menu consists of the five function keys as shown below. The twodots after the function key name indicate that there will be another menudisplayed when the function key is pressed.

Figure 4.1-3 EasyArc Main Menu

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4.2 Setup Menu

When the SETUP.. key is pressed, the Setup Menu will be displayed:

Figure 4.2-1 Setup Menu

The Setup menu can be accessed in the MANUAL mode only. If you pressthe SETUP.. key in the AUTO mode, the message "Menu not Available inAUTO" will be displayed on the screen.

4.2.1 If the Setup Cell menu item is selected by pressing function key 1 inthe Setup Menu, the Cell Setup menu is displayed.

Figure 4.2-2 Cell Setup Menu

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Press CLOSE to exit the Cell Setup menu and return to the Setup Menu.

The operation of the Cell Setup menu was explained starting at section3.1.3.

4.2.2 If you have loaded the BullsEye option modules, Setup BullsEye willappear as one of the menu items. If you press the associated function key,the BullsEye setup routine will be run. If you have not loaded the BullsEyeOption, this menu item will not appear on the menu.

4.2.3 If you have loaded a torch clean module that has a setup routine, Setuptorch cleaner will appear as one of the menu items. If you press theassociated function key, the torch clean setup routine will be run. If you havenot loaded a torch cleaner module with a setup routine, this menu item willnot appear on the menu.

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4.3 Test Menu

When the Main Menu (Figure 4.1-3) is displayed, pressing the TEST..function key activates the Test Menu.

Figure 4.3-1 Test Menu

This menu is used for testing part programs.

The Test menu can be accessed in the MANUAL mode only. If you press theTEST.. key in the AUTO mode, the message “Menu not Available in AUTO”will be displayed on the screen.

Press the function key CLOSE to exit the Test Menu and return to the MainMenu.

If the operator selects the Run station 1 menu item by pressing the functionkey 1 in Figure 4.3-1, the current active program on station 1 will be run, thenthe robot will move back to the safe position. The current program isdisplayed on the menu after Run station 1:. When the program finishes, theTest Menu will be displayed again.

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4.4 Manual Operations Menu

When the Main Menu (Figure 4.1-3) is displayed, pressing the MANOP..function key activates the Manual Operations Menu:

Figure 4.4-1 Manual Operations Menu

Pressing the function key CLOSE exits the Manual Operations Menu andreturns to the Main Menu.

4.4.1 When the Robot menu item is selected by pressing the function key 1,the Manual Operations: Robot menu is displayed:

Figure 4.4-2 Manual Operations: Robot Menu

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Pressing CLOSE exits the Manual Operations: Robot menu and returns tothe Manual Operations Menu.

4.4.1.1 When the Move to Calibration position item is selected by pressingfunction key 1, the program will move the robot to a calibration position thatthe operator chooses from the menu.

Figure 4.4-3 Calibration position Selection

If the function key NORMAL is selected, the robot will make a move to a jointtarget with 0° for all axes.

If the function key LEFT is selected, the robot will make a move to a jointtarget with -90° for axis 1 and 0° for all other axes.

If the function key RIGHT is selected, the robot will make a move to 90° foraxis 1 and 0° for all other axes.

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When one of the calibration positions has been selected, the programdisplays a movement caution:

Figure 4.4-4 Move to Calibration position Warning

The screen displays the robot axis positions for the selected calibrationposition.If the operator presses CANCEL, the robot will not move to the calibrationposition, and the Manual Operations: Robot menu will be displayed again. Ifthe operator presses OK the robot will move to the selected calibrationposition. EasyArc will then display the following screen:

Figure 4.4-5 Calibration position Screen

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If you press PROCEED the program will ask if it is OK to move to the SAFEposition:

Figure 4.4-6 Move to SAFE Caution Screen

Press OK to move to the SAFE position or CANCEL to stay at the calibrationposition and return to the Manual Operations: Robot menu Figure 4.4-2.

If you select the Calibrate Robot item in AUTO mode, the following messagewill be displayed:

Figure 4.4-7 Not Allowed in Auto Mode Screen

Press PROCEED to exit this display and return to the Manual Operations:Robot Menu.

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4.4.1.2 If a Park position for the cell was activated in the cell setup process,the menu item the Move to Park position will appear on as item 2 of theManual Operations: Robot Menu. Selecting this menu item will move therobot to the Park position. Before the robot moves, the following caution isdisplayed:

Figure 4.4-8 Move to Park position Screen

Press OK to move to the Park position or CANCEL to return to the ManualOperations: Robot Menu.

4.4.1.3 If the operator selects the Move to Safe position menu item of theManual Operations: Robot Menu the robot will move to the SAFE position.Before the robot moves to the SAFE position, the following caution isdisplayed:

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Figure 4.4-9 Move to SAFE position ScreenPress OK to move to the SAFE position or CANCEL to return to the ManualOperations: Robot Menu.

4.4.1.4 If the operator selects the Move to SERVICE position menu item ofthe Manual Operations: Robot Menu the robot will move to the SERVICEposition. Before the robot moves to the SERVICE position, the followingcaution is displayed:

Figure 4.4-10 Move to SERVICE position Screen

Press OK to move to the SERVICE position or CANCEL to return to theManual Operations: Robot Menu.

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4.4.2 When the Positioner menu item is selected by pressing the functionkey 2 in the Manual Operations Menu (Figure 4.4-1), the ManualOperations: IRBP Menu is displayed:

Figure 4.4-11 Manual Operations: IRBP

Pressing CLOSE exits the Manual Operations: IRBP menu and returns tothe Manual Operations Menu.

4.4.2.1 When the Move station to an angle menu item is selected bypressing function key 1 on the Manual Operations: IRBP Menu, thepositioner angle entry screen will be displayed:

Figure 4.4-12 Positioner Angle Entry Display

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The operator will enter the desired angle (in degrees) from the pendantnumeric keypad and press the OK function key. When this occurs, theMovement Caution Display will appear:

Figure 4.4-13 Station Movement Caution Display

When the operator presses OK, the positioner will move to the angledisplayed. If the operator presses CANCEL no movement will occur and theManual Operations: IRBP menu will appear again (Figure 4.4-11).

4.4.2.2 When the function key 3 is pressed on the Manual Operations: IRBPmenu, all the external axes will be deactivated.

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4.4.3 When the Tool menu item is selected by pressing the function key 3 inthe Manual Operations Menu (Figure 4.4-1), the Manual Operations: ToolMenu is displayed:

Figure 4.4-15 Manual Operations: Tool Menu

If one of the tool modules, MIG, Mig_Awc, or MIG_A was loaded, Servicetool and Move robot to safe position will appear as menu items 1 and 2. Ifthese tool modules were not loaded, these items will not appear on the menu.

Menu item Check TCP will only appear if the BullsEye option has beenloaded and menu item Clean tool will only appear if the torch clean optionhas been loaded.

If no tool module has been loaded, no torch cleaner module has beenloaded, and BullsEye has not been loaded, EasyArc will display the followingmessage:

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Figure 4.4-16 Manual Operations: Tool Menu

Press the CLOSE function key to exit the Tool menu.

4.4.3.1 When the Service Tool menu item is selected by pressing the 1function key, the robot will move to the SERVICE position. Before movement,the Move to SERVICE position Screen will appear (See Figure 4.4-9). If theoperator presses OK, the robot will move to the SERVICE position.

When the robot reaches the SERVICE position, the Service Tool Menu willbe displayed:

Figure 4.4-17 Service Tool Menu

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When the Check gas flow menu item is selected by pressing the functionkey 1 in the Service Tool Menu. The Check Gas Flow screen will appear:

Figure 4.4-18 Check Gas Flow Screen

Press ON to turn on the gas solenoid. When this is done the program willdisplay this screen:

Figure 4.4-19 Gas Solenoid On Screen

EasyArc will check to see if the input from the gas/water sensor turns on, anddisplay the results on the pendant:

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Figure 4.4-20 Gas Solenoid Test Screen

Press OFF to turn the gas solenoid off or press CLOSE to exit the Check GasFlow display and return to the Service Tool Menu.

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If the Mig tool module was loaded, when the Feed wire menu item isselected by pressing the function key 2 in the Service Tool Menu, the FeedWire screen will appear:

Figure 4.4-21 Feed Wire Screen

Press FEED to feed wire. 15 mm is the default length of wire to be fed.

If the CHANGE function key is pressed, the operator will be asked to enter anew length of wire to be used in this function:

Figure 4.4-22 Change Feed Wire Length Screen

Enter the new length of wire to be used in the wire feed function and pressOK.

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When the FEED key is pressed, the wire feeder will feed out approximatelythe amount of wire selected. While the feeder is on, the following screen willbe displayed the pendant:

Figure 4.4-23 Feeding Wire Screen

If MIG_AWC or MIG_A were loaded, the preceding screens would displaytime instead of length as the feed wire units.

When the Check air blast menu item is selected by pressing the function key3 in the Service Tool Menu, the Check Air Blast screen will appear:

Figure 4.4-24 Check Air Blast Screen

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When the operator presses the CHECK function key, the air blast solenoidturns on for 2 seconds with the following screen and then returns to theCheck Air Blast screen.

Figure 4.4-25 Air Blast Solenoid On Screen

Press CLOSE to exit the Check Air Blast screen and return to the ServiceTool Menu.

NOTE: The air blast function is a standard feature of EasyArc, but may notbe present depending on the equipment present in the cell. If an air blastsolenoid is not present, the gas solenoid will be turned on by this menu item.

Press CLOSE to exit the Service Tool Menu (Figure 4.4-17) and return tothe Manual Operations: Tool menu (Figure 4.4-15). If the robot was movedfrom the SAFE position by one of the manual operations, the followingmessage will be displayed:

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Figure 4.4-26 Movement Caution Screen

Press OK if it is OK to move to the SAFE position or CANCEL if not OK. Stopthe program an jog the robot to a SAFE position and start again.

4.4.3.2 Selecting the Move to Safe position menu item of the ManualOperations: Robot Menu will move the robot to the SAFE position in thecurrent station. This operation was described in section 4.4.1.2.

4.4.3.3 If the BullsEye modules were loaded, Check TCP will appear as amenu item, if not, Check TCP will not appear on the menu. When the CheckTCP menu item is selected by pressing the associated function key, the TCPcheck program will be run.

4.4.3.4 If a Torch clean module was loaded, Clean tool will appear as amenu item, if not, Clean tool will not appear on the menu. When the Cleantool menu item is selected by pressing the associated function key, the torchclean program will be run.

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4.5 Production Setup Menu

When the Main Menu (Figure 4.1-3) is displayed, pressing the PROD..function key activates the Production Menu:

Figure 4.5-1 Production Menu

This menu allows the operator to select the weld program that will be runwhen the operator ready push button is pressed, select the TCP checkfrequency, and select the torch clean frequency. The TCP and torch cleanmenu items will only appear if these options were loaded.

Press the function key CLOSE to exit the Production Menu and return to theMain Menu.

4.5.1 When the Select program station 1 menu item is selected by pressing1 in the Production Menu, the Program Selection menu for Station 1 will bedisplayed. This menu shows the contents of the weld program list for station1 and allows you to select a weld program from the list to run on station 1.(See section 5 Adding Weld Programs)

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Figure 4.5-2 Program Selection Menu (page 1)

When the operator presses function key MORE, the second page (if required)of the Station 1 Program Selection menu will be displayed:

Figure 4.5-3 Program Selection Menu (page 2)

When the operator presses function key BACK, the first page of the PartSelection Menu Station 1 will be displayed again

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When the operator selects a menu item to activate a program for station 1,the program confirmation screen is displayed.

Figure 4.5-4 Program Confirmation Screen

The operator must select a program to exit the Program Selection menu forstation 1. If the operator presses Cancel, the program will return to theProgram Selection menu for station 1.

The operator must press Confirm to activate the selected program for station1. When the operator presses Confirm, EasyArc will ask if you want to resetthe program counter for station 1:

Figure 4.5-5 Part Counter Reset Screen

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If you press OK the counter will be reset, if you press CANCEL the counterwill retain the value shown on the screen. The Production Menu will bedisplayed again (Figure 4.5-1).

4.5.2 If the BullsEye and TCPData modules were loaded, the Change TCPCheck frequency menu item will appear in the Production Menu. When thismenu item is selected by pressing the associated function key, the TCPCheck Frequency screen will be shown. This screen allows you to enter aTCP check frequency for the cell.

Figure 4.5-6 TCP Check Frequency Screen

The operator then enters the desired number of cycles of the weld programbetween TCP checks from the pendant keypad and presses OK. If theoperator enters 0 or presses OK without entering a number, TCP checking isdisabled (this is the default condition). The operator must press OK to exitthis menu and return to the Production Menu.

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4.5.3 If a torch clean module was loaded, the Change torch cleanfrequency menu item will appear on the menu. When this menu item isselected by pressing the associated function key on the Production Menu,the Torch Clean Frequency display will be shown. This display allows you toenter a torch clean frequency for the cell.

Figure 4.5-7 Torch Clean Frequency Screen

The operator then enters the desired number of cycles of the weld programbetween torch cleanings from the pendant keypad and presses OK. If theoperator enters 0 or presses OK without entering a number, torch cleaning isdisabled (this is the default condition). The operator must press OK to exitthis menu and return to the Production Menu.

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4.6 Information Menu

When the Main Menu (Figure 4.1-3) is displayed, pressing the INFO..function key activates the Information Menu:

Figure 4.6-1 Information Menu

Press the function key CLOSE to exit the Information Menu and return tothe Main Menu.

4.6.1 If the Production selections menu item is selected by pressing thefunction key 1, the Production Selections display will be shown.

Figure 4.6-2 Production Selections Display

This display allows you to view the current production setup for the cell.

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The operator presses function key CLOSE to exit the Production Selectionsdisplay and return to the Information Menu.

4.6.2 If the Station statistics menu item is selected by pressing the functionkey 2 in the Information Menu, the station 1 Statistics display will be shown.This display allows you to view station statistics.

Figure 4.6-3 Station 2 Statistics Display

The operator must press CLOSE to exit the Statistics display and return tothe Information Menu.

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4.6.3 If the Versions menu item is selected by pressing the function key 3 inthe Information Menu, the module Versions display (page 1) will be shown.This display allows you to view the versions of the software modules youhave loaded.

Figure 4.6-4 Module Versions Display page 1

When the operator presses function key MORE, the second page (if required)of the module Versions display will be shown:

Figure 4.6-5 Module Versions Display page 2

When the operator presses function key CLOSE, the Information Menu willbe displayed again.

4.7 Cell Operation

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This section describes the operation sequence that occurs during normaloperation of the cell when the operator presses the Operator Readypushbutton.

When the Main Menu (Figure 4.1-3) is displayed, pressing the OperatorReady pushbutton starts the following sequence of events:

1. The operator ready lamp will turn on. If the cell is equipped with a safetydoor, the door will close.

2. The Main Menu is erased from the screen and the operator can no longeraccess the EasyArc menus.

3. If the optional Park position was activated and defined during cell setup(See Section 3.1.6), the robot will move to the Safe position.

4. The operator ready will be reset from EasyArc.

5. EasyArc will run the current active program for this station (See Section4.5) and display information about the program on the teach pendant:

Figure 4.7-1 Part program information display

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6. When the program has been completed, information regarding theprogram will again be displayed:

Figure 4.7-2 Part program information display

7. If a BullsEye is present in the cell, and it is time to check the TCP, theTCP check routine will be run. (See Section 4.5 Production Menu)

8. If a torch cleaner is present in the cell, and it is time to clean the weldingtorch, the torch clean routine will be run. (See Section 4.5 ProductionMenu)

9. EasyArc will deactivate all IRBP axes, and the robot will return to the Safeposition and then Park position (if active).

10. If the cell is equipped with a safety door, the door will open.

11. The EasyArc Main Menu will then be displayed again:

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Figure 4.7-3 Main Menu

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5. Adding Weld Routines

The process of creating and adding a weld routine to the program list for a particularstation is described in this section. Once a weld routine has been created and itsname has been added to the program list for a particular station, it will appear as amenu selection in the Program Selection menu for that station. (See sections 4.5.1and 4.5.2)

5.1 Creating a Weld Program

The operator must first create a new weld routine and add the necessaryinstructions for welding the desired part. For example, if you wanted to create aweld routine for station 1:

1. Select VIEW; 6 Modules.

Figure 5-1 View Modules

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2. Move the cursor to the module WeldPrg1 which will contain the weld routinesfor station 1 that you create:

Figure 5-2 Select module WeldPrg1

3. Press “Enter” to display the routines in WeldPrg1:

Figure 5-3 Routines in WeldPrg1

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4. Press “New” to create a new routine:

Figure 5-4 New Routine

5. Press “Enter” and change the name of the routine as desired:

Figure 5-5 Name the New Routine

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6. Press “OK” to accept the new routine name:

Figure 5-6 Routine MYPROG

7. Press “OK” to define the new routine “MYPROG”:

Figure 5-7 Routines in WeldPrg1

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8. Press “ENTER” to view the new routine “MYPROG”:

Figure 5-8 Weld Routine “MYPROG”

9. You should now proceed to add your welding instructions to this routine:

Figure 5-9 Weld Instructions in “MYPROG”

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The routine can be tested, and modified as required. Move the programpointer to the routine:

Figure 5-10 Move Program Pointer to routine

Move the cursor to the routine you want to test and press “OK”:

Figure 5-11 Select routine MYPROG

You can now run the routine and test your weld instructions.

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5.2 Adding a Weld Program to the Program List

Once the weld routine has been created, programmed, and tested, the operatorshould add this routine’s name to the program list for the station on which it wasprogrammed (in this example Station 1)

For example, you would add the routine “MYPROG” to the program list forStation 1 by doing the following:

1. Select VIEW; Modules.


The list of modules will be displayed on the pendant screen.

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2. Move the cursor to the module WeldPrg1 which contains the weld routinesfor station 1:

Figure 5-13 Select WeldPrg1 module

3. Press "ENTER" on the pendant to display the weld routines in WeldPrg1module.

Figure 5-14 Select WeldPrg1 module

Move the cursor to the routine InitProgSta1. Press "ENTER" on the pendant todisplay the instructions in this routine.

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Figure 5-15 View InitProgSta1 Routine

You can hide the Pick list by selecting Edit; Hide IPL:

Figure 5-16 Hide IPL

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4. Move the cursor to the first line with an empty name:

Figure 5-17 Move to Line with Empty Name

5. Move the cursor to the empty string:

Figure 5-18 Move to Empty Name

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6. Press Enter. This will display the current value of the string:

Figure 5-19 Name Value Screen

7. Press Text.. to edit the value of the string:

Figure 5-20 Name Entry Screen

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8. Change the string to the name “MYPROG”:

Figure 5-21 Name Entry Screen

Press “OK” to enter the new value:

Figure 5-22 New String Value Screen

Double check the spelling of this name. Upper/Lower case does notmatter. Press “OK” to accept the new name or press Text.. to edit thename.

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Figure 5-23 New Name in Station 1 Program List

If you want to remove an item from the program list, modify the item name from:stProgListSta1{3}:="MYPROG";

to:

stProgListSta1{3}:="";

9. You can restore the Instruction Pick list by pressing “Edit”; “9 Show IPL”:

Figure 5-24 Show the Instruction Pick List

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5.3 Activating a Program

Activating a program is a means of telling EasyArc which program you want torun.

1. Run the program from main by pressing “Test->” in Figure 5-12. Select“Special”; ”3 Move PP to Main”. Press Enter.

Figure 5-25 Move Program Pointer to Main

Then press Start. EasyArc will start. (See Section 4)

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2. From the Main Menu (See Figure 4-2), press the "PROD.." function key todisplay the Production Menu:

Figure 5-26 Production Menu

3. Pick the “Select program station 1” menu item by pressing "1". Thecontents of the program list for station 1 will be shown as a menu:

Figure 5-27 Program Selection Menu

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4. Select the menu item “MYPROG” by pressing “2”. The programconfirmation screen is displayed.

Figure 5-28 Program Selection Confirmation Screen

5. The operator must press “Confirm” to activate “MYPROG” for station 1 andreturn to the Production Menu or press “Cancel” to return to the ProgramSelection menu for station 1. When you press “Confirm”, you will be askedif you want to reset the part counter on station 1:

Figure 5-29 Program Selection Confirmation Screen

Press “OK” or “CANCEL”

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The Production Menu will now look like this:

Figure 5-30 Production Menu

The Test Menu for station 1 will now show the new active program.

Figure 5-31 Test Menu

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6. Stop the program and save the program. Select FILE; then Save Program.

Figure 5-32 Save Program

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6. Adding Error Handlers

Once your weld routines have been written, you can add error handlers to theroutines. This allows your programs to detect errors when they occur and move therobot to a position where the tool can be serviced easily. A service menu will bedisplayed to assist the operator in the process of servicing the tool.

The Tool modules (i.e. Mig, Mig_A etc.) contain error handling routines and anexample routine with the standard error handler: ErrExample.

6.1 Adding an Error handler to a weld routine

For example, if you have created a weld routine called MyProg on station 1, youwould add an error handler to the routine by doing the following:

1. Select View; 6 Modules:


2. Move the cursor to WeldPrg1:

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Figure 6-2 Select Weld Program Module Station 1

3. Press ENTER on the pendant to display the routines in the WeldPrg1module.

Figure 6-3 View Routines

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4. Move the cursor to the routine MyProg

Figure 6-4 Select Weld Program

5. Press the Routine function key on the Teach Pendant and then select item 7Add Error Handler.

Figure 6-5 Select Add Error Handler

This adds an error handler to your weld routine MYPROG.

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6. Select View; 6 Modules.


7. Move the cursor to Mig, Mig_A, or Mig_AWC, whichever option you haveloaded, and press Enter.

Figure 6-7 Select Mig Module

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8. Move the cursor to the routine ErrExample and press Enter.

Figure 6-8 Select Example

9. Press View; then press 9 Error Handler.

Figure 6-9 Select View Error Handler

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10. Press Copy to copy this example error handler.

Figure 6-10 Copy Example Error Handler

11. Select View; Modules. Move the cursor to WeldPrg1 and press Enter.Move the cursor to the routine MyProg and press Enter . See steps 1through 4.

12. Press View; then press 9 Error Handler.

Figure 6-11 Copy Example Error Handler

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13. Press Paste to paste the example error handler into the weld routine.

Figure 6-12 Paste Error Handler into MYPROG

The weld program MYPROG now contains an error handler.

6.2 Modifying the Error Handler (ErrExample)

The error handler should now be modified for use in your weld routine. TheErrExample error handler looks like this:

TEST ErrComHandler() CASE 1: RETRY; CASE 3: RETURN; CASE 4: ! ! Press Forward step Stop; RETURN; CASE 5: RAISE; ENDTEST

Only one modification can be made here. The ErrComHandler function calls ageneric error handling structure. A StopKey switch is available in some versionsof the Mig tools module. At the time of this printing, only Mig_Awc tools modulehas this option. If selected, the menu displayed when a process error occurs,will have a Stop selection button. When not selected, a Raise selection buttontakes its place. Note: The StopKey option is only available in Mig_AWC 4.0and higher. A detailed explanation for ErrComHandler is provided in Appendix 6.

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When the function ErrComHandler is called in the TEST instruction, it will firstdisplay the following menu:

Figure 6-13a Mig Error Screen Without StopKey Selected

Figure 6-13b Mig Error Screens With StopKey Selected

Raise:If the operator selects Raise, the error will be raised to the next level. If thecalling routine at this level has no error handler, the error will not be handled, anexecution error will be flagged, and program execution will stop. Occasionallythere may be a need to move the Program Pointer out of the error handler andback to the weld instruction that caused the error. The Raise key allows a wayto do this without loosing program context.

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�� Important: Never relocate the program pointer within the error handlingroutine! A Path Limit error will occur with the next weld error.

Stop:The Stop key is available in some versions of the Mig tools module. It’s purposeis essentially the same as the Raise key, but it is used where the weld routine isnested inside a routine with its own error handler. By selecting the Stop feature,program execution stops. Forward stepping allows the operator to escape theerror handler without jumping into the error handler of the next routine. For moreinformation, see Appendix 6 – ErrComHandler.�� Important: Never relocate the program pointer within the error handlingroutine! A Path Limit error will occur with the next weld error.

Retry:If the operator presses Retry, the error handler will first burn off the weld wire byturning on the welding power supply momentarily, then it will retry the weld.

MoveOut:If the operator presses MoveOut, the error handler will burn off the weld wire byturning on the welding power supply momentarily, then move the torch out of theweld path either relative to the tool (RelTool), or with to an offset from the pointwhere the error occurred (Offs).

The type of initial move is set by calling the procedure, DefEscapePath, beforebeginning a weld:

PROC ErrExample() DefEscapePath “ErrWeldExample1”; MoveJ *......; ArcL/On......; ArcL......; DefEscapePath “”\Offset\Z_Value:=75; ArcL/Off......; MoveJ *......; ERROR

Note that DefEscapePath has a number of different forms and can provide avariety of effects. Both the initial move criteria and the escape path are definedby DefEscapePath.

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In the first call:

DefEscapePath “ErrWeldExample1”;

The escape path is described in routine ErrWeldExample1. The initial move is aRelTool move by default of 50mm.

In the second call:

DefEscapePath “”\Offset\Z_Value:=75;

The escape path is not defined, so no escape path will be executed. However,the initial move will still be executed. In this case it is an Offs (Offset) type moveof 75mm in the Z direction. More detailed information about the initial Move Out,and DefEscapePath in general, can be found in Appendix 6.

After the robot executes the initial move out, following menu is displayed:

Figure 6-14 Mig Error Menu

If the operator presses RETRY, the robot will move back into the seam and retrythe weld.

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If the operator presses ServGun the Service Weld Gun menu will be displayed:

Figure 6-15a Service Weld Gun Menu

If the operator presses ServPos (See Figure 6-14), the robot will move to aservice position by calling the path routine named in the first optional argumentto DefEscapePath (i.e. PathOut_1 in this example). The robot will return to theweld seam from the service position by replaying the points in PathOut_1 inreverse. The routines describing the escape paths should be declared in theweld program module, in this case WeldPrg1. All the robot movements requiredfor movement to the service position from the initial MoveOut position must becorrectly defined. A typical path routine will look like this:

PROC PathOut_1() MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun;ENDPROC

MoveErrPth executes similarly to a MoveL or MoveJ, with the added feature ofpath storage for replay in reverse. More information can be found about thefunctionality of MoveErrPth in Appendix 6. In non-FlexArc® systems, the lastpoint in the escape path routine should be programmed to be at a serviceableposition, unless the optional argument ServPos is selected for DefEscapePath.When the optional argument is selected the robot will automatically move to thecell’s Service Position after the reaching last point in the escape path routine.This optional argument has no affect in FlexArc® systems.

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An example of DefEscapePath used with the optional argument, ServPos:

DefEscapePath “PathOut_1”\ServPos;

DefEscapePath can be modified to follow other path routines to and from theservice position by moving the cursor to the line:

DefEscapePath “PathOut_1”;

then changing the name of the path routine.

An empty string:

DefEscapePath “”;

indicates that the robot should not be allowed to move to a service position.

Once the operator selects the ServPos option, the robot will move to the serviceposition and the Service Weld Gun menu will again appear (See Figure 6-15). InFlexArc® systems, the menu will have a forth option to move to the serviceposition inside the service access portal:

Figure 6-15b Service Weld Gun Menu

When the option is selected to move to the service position, the robot will moveinto the access portal. For FlexArc® systems, the last point defined in theescape path routine is not the final service position, but rather an approachposition, allowing access to the portal. At this point the Service Weld Gun menuwill change to give an option to move back out of the access portal to the serviceapproach position:

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Figure 6-15c Service Weld Gun Menu

When the operator is finished servicing the weld gun and presses CLOSE thefollowing message will appear:

Figure 6-16 Return to MoveOut Point Above Seam

If the operator presses CANCEL, the Service Weld Gun menu (See Figure 6-15a,b,c) will be displayed again. If the operator presses OK, the robot will returnto the initial Move Out point above the seam and offer the prompt:

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Figure 6-17 Return to Seam and Retry

If the operator presses OK, the robot will return to the weld seam and retry theweld. If the operator presses CANCEL, the Service Weld Gun menu (See Figure6-15) will be displayed again.

Error Handling Instructions Appendix 6

Revision 1.1 – MIG modules rev 4.1

DefEscapePath defines the escape path routine to use

DefEscapePath defines which routine to execute in case an error occurs.The instruction needs to be executed before the welding starts andapplies to all subsequent welds, until updated.

Example

DefEscapePath "ErrWeldExample2";

For all welds after this instruction, if an error occurs during welding,the initial move (Move Out) from the seam will be a Relative ToolMove. The default values for the initial move are: 0mm in x, 0mmin y, and –50mm in z. The escape path executed after the initialmove (Move Out) is prescribed by the procedure ErrWeldExample2.

ArgumentsDefEscapePath OutPath [\Offset] [\X_Value] [\Y_Value] [\Z_Value] [ServPos]

OutPath Data type: string

Defines the name of the routine to execute. An empty string “” will resetthe escape path and indicate that no path out is to be executed.

\Offset Data type: switch

If present, the initial move (Move Out) will be an Offset move relative tothe current work object. If not selected the initial move will be a RelToolmove.

\X_Value Data type: num

The distance (mm) the initial move will translate in the x-direction. Thedefault value, if not selected, is zero.

\Y_Value Data type: num

The distance (mm) the initial move will translate in the y-direction. Thedefault value, if not selected, is zero.

\Z_Value Data type: num

The distance (mm) the initial move will translate in the z-direction. Thedefault value, if not selected, is zero for Offset moves, and 50mm forRelTool moves. For RelTool moves, the sign of the number isunimportant.



\ServPos Data type: switch

If selected, the robot will move to the Service Position automatically afterexecuting an escape path. This feature only applies to ABB WSDstandard welding cells (not FlexArcs).

Program Execution

When executed, the procedure sets the escape path routine name, andinitial move type, direction, and magnitude. These remain active untilchanged by executing DefEscapePath again.

- DefEscapePath may be called in the middle of a weld.- Setting the OutPath to the empty string, “”, denies the use of

an escape path, but maintains the initial move (Move Out)described in the rest of the instruction.

- If an error handler is called, and an empty string was selected,or DefEscapePath was never executed, a warning will appearon the teach pendant and require acknowledgement.Execution will continue, and the weld process may berestarted.

Examples

DefEscapePath "";

The torch will pull out 50mm in Z (inline with torch), but no path will beexecuted.

DefEscapePath ""\Z_Value:=0;

The torch will not pull out at all and no path will be executed.

DefEscapePath ""\Offset;

The torch will not pull out at all and no path will be executed.

DefEscapePath ""\Offset\Z_Value:=75;

The torch will move 75mm in Z (based on current work object), but nopath will be executed.

DefEscapePath "ErrWeldExample2";

The torch will pull out 50mm in Z (inline with torch), and the pathprescribed in ErrWeldExample2 will be executed.

DefEscapePath "ErrWeldExample2"\X_Value:=-20;



The torch will pull out 50mm in Z (inline with torch) and –20 in X. Thepath prescribed in ErrWeldExample2 will be executed.

PROC ErrExample() DefEscapePath "ErrWeldExample1"; MoveJ *......; ArcL/On......; ArcL......; DefEscapePath ""\Offset\Z_Value:=75; ArcL/Off......; MoveJ *......; ERROR TEST ErrComHandler() CASE 1: RETRY; CASE 3: RETURN; CASE 4: ! ! Press Forward step Stop; RETURN; CASE 5: RAISE; ENDTEST ENDPROC

PROC ErrWeldExample1 () MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun;ENDPROC

PROC ErrWeldExample2 () MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun;ENDPROC

Here, DefEscapePath is used twice in the same weld to describe twodifferent escape paths for two areas of the same weld seam.

DefEscapePath "ErrWeldExample2"\ServPos;

The torch will pull out 50mm in Z (inline with torch), and the pathprescribed in ErrWeldExample2 will be executed. The robot willautomatically move to the cell’s “Service Position” after executing thepath in ErrWeldExample2. This option applies to ABB WSD Standardsystems. FlexArc® systems are unaffected.



Syntax

DefEscapePath[ OutPath ’:=’ ] < expression (IN) of string > ’,’[‘\ ‘Offset’,’][‘\ ‘X_Value’:=’ < expression (IN) of num > ] ’,’[‘\ ‘Y_Value’:=’ < expression (IN) of num > ] ’,’[‘\ ‘Z_Value’:=’ < expression (IN) of num > ] ’,’[‘\ ‘ServPos] ‘;’

Related informationDescribed in:

MoveErrPth EasyArc Appendix 6Offs (Offset) Rapid Reference functionsRelTool Rapid Reference functionsErrComHandler EasyArc Appendix 6



ErrComHandler common error handler for all weld routines

The ErrComHandler function calls a generic error handling structure,which can be customized in a number of ways to provide safe passage toand from the point where a process error has occurred, and a serviceposition. It is intended for use in an error handler.

Arguments

ErrComHandler [\StopKey]

[\StopKey] Data type: switch

If selected, the menu displayed when a process error occurs, will have aStop selection button. When not selected, a Raise selection button takesit’s place. Note: The StopKey option is only available in Mig_AWC 4.0and higher.

Program execution

Intended for use in an error handler, when executed, the functionidentifies the error that has occurred and prompts the user for a course ofaction. The operator chooses from a list of options, which may includemoving the robot to a service position, servicing the tool, and returning tothe weld. Raise or Stop may be selected to escape the error handler andreturn to the calling routine. Note: The Stop option is only available inMig_AWC 4.0 and higher.

LimitationsIt is not advisable to move the program pointer around inside the errorhandler. Program context can be lost. Although unadvisable, it ispossible to move the program pointer out of the error handler completely.The preferred method for escaping from the error handler and returning tothe calling routine, is to select Raise or Stop from the error handler menuwhile program execution continues. Note: The Stop option is onlyavailable in Mig_AWC 4.0 and higher.



Example

PROC ErrExample() DefEscapePath ""; MoveJ *......; ArcL/On......; ArcL/Off......; MoveJ *......; ERROR TEST ErrComHandler() CASE 1: RETRY; CASE 3: RETURN; CASE 4: ! ! Press Forward step Stop; RETURN; CASE 5: RAISE; ENDTEST ENDPROC

Syntax

ErrComHandler’(‘[‘\ ‘StopKey]’)’

returns type num


DefEscapePath EasyArc Appendix 6Error Recovery Rapid Reference Basic

CharacteristicsMoveErrPth EasyArc Appendix 6System Requirements EasyArc Appendix 6



MoveErrPth Move L or J used for escape path

The MoveErrPth instruction is used for moving the robot in an errorrecovery path. When using the instruction the points will be stored in anarray. The array can then be used to move the robot back to the errorlocation.

ArgumentsMoveErrPth [\J] ToPoint [\Ext1] [\Ext2] [\Ext3] [\Ext4] [\Ext5] [\Ext6] SpeedTool [\Wobj]

[\J] Data type: switch

If selected, a joint move will be made otherwise a linear move is made.

ToPoint Data type: robtarget

The destination position of the robot and external axes. This is eitherdefined as a named position or stored directly in the instruction (indicatedby an * in the instruction).

[\Ext1] - [\Ext6] Data type: switch

If selected, the external axes will remain in its present location.

Speed Data type: speeddata

The speed of the TCP.

Tool Data type: tooldata

The tool used in the movement. The TCP of the tool is the point moved tothe specified destination position. The z-axis of the tool should be parallelwith the torch.

[ \WObj] Data type: wobjdata

The work object (coordinate system) to which the robot position isreferenced.

When this argument is omitted, the robot position is referenced to theworld coordinate system. It must, however, be specified if a stationaryTCP or coordinated external axes are used.



Program execution

When executed, the instruction behaves similarly to a MoveJ or MoveL,however when used as an escape path for a process error handler, thepoints are saved and replayed in reverse to return to the point where theerror occurred. When programming escape paths, only the pathdescribing the movement away from the error location, needs to beprogrammed.

LimitationsKeep in mind that if the robot has not actually executed and passedthrough the points on the escape path, no points will be stored, andattempts to return to the point of error will be unsuccessful.

Fault management

ERRORRAISE;

Example

PROC ErrWeldExample1() MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun;ENDPROC

PROC ErrWeldExample2() MoveErrPth *,v200,tWeldGun; MoveErrPth *,v200,tWeldGun; MoveErrPth pServSta1,v200,tool0;ENDPROC



PROC ErrExample() DefEscapePath "ErrWeldExample1"; MoveJ *......; ArcL/On......; ArcL/Off......; MoveJ *......; ERROR TEST ErrComHandler() CASE 1: RETRY; CASE 3: RETURN; CASE 4: ! ! Press Forward step Stop; RETURN; CASE 5: RAISE; ENDTEST ENDPROC

Here, MoveErrPth is used two describe two paths away from the weldseam. In this case two different paths were required for two differentportions of the weld seam.

Syntax

MoveErrPth[‘\ ‘J’,’][ ToPoint ’:=’ ] < expression (IN) of robtarget > ’,’[‘\ ‘Ext1’,’][‘\ ‘Ext2’,’][‘\ ‘Ext3’,’][‘\ ‘Ext4’,’][‘\ ‘Ext5’,’][‘\ ‘Ext6’,’] [ Speed ’:=’ ] < expression (IN) of speeddata >’,’ [ Tool ’:=’ ] < persistent (PERS) of tooldata > ’,’[ ’\’ WObj ’:=’ < persistent (PERS) of wobjdata >] ’;’


DefEscapePath EasyArc Appendix 6MoveL Rapid Reference functionsMoveJ Rapid Reference functionsErrComHandler EasyArc Appendix 6

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