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    1INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BFanuc Robots with Device NetJDS402 – DELTA Robot Programming

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    2INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BPage Description3. 1K Systems Overview6.1K Components9.1K Controls13.1K System Dispense Head Checking Procedure14.1KC Overview15.1KC Components18.1KC Controls20. Dispensing Methods 23. Nozzle Selecting26. Temperatu...

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    3INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsOverviewThe 1K systems use a shot meter as a metering device. The shot meter works by using displacement as a method of dispensing material.The faster and harder the piston rod is moved into the material vesse...

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    4INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsOverviewMain Components:Linear Transducer MLDT Electrical ConnectorAir Servo ValveAir CylinderSolenoid ValvesPiston RodSeal CartridgePSI TransducerRefill Valve (behind material hose block)Material VesselDispens...

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    5INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsOverviewLinear Transducer:Tells the system how much material has been dispensed.Refill Solenoid Valve:When energized opens the refill valve.Piston Rod:Used to displace the material in the dispense chamber.Refil...

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    6INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsComponentsMLDT Magnetostrictive Linear Displacement TransducerPart No. 75cc 364-650Voltage Input 24vdcVoltage Output 0-10vdcOperationAt the start of the dispense cycle the PC takes a voltage reading (style s...

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    7INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsComponentsPressure Transducer:Part No. 363-314The pressure transducer tells the 1K system how much pressure is in the dispense chamber. It is designed so that it is flush mount. This prevents material from pac...

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    8INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsComponentsAir IntensifierPart No. 364-661An air intensifier is used to increase the dispense pressure of a 1K dispensing head.This allows the size of the control valves and air cylinder to be smaller and have ...

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    9INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsComponentsAir Servo Valve: Part No. 354-515When the system is not in a dispense mode (Gun Off) the Servo signal will be at 5V. At 5v the same pressure should appear on both sides of the Air Cylinder (within...

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    10INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsPressure LoopPressure Loop: If the robot velocity increases, the output is above 5V when the pressure transducer feedback is subtracted from it. A signal higher than 5V causes the Servo Valve to send maximum p...

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    11INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsPressure LoopThe Robot Flow Command signal will change the pressure in the dispense head. The range of the robot flow command signal is from 0-4095 (0-10V). The maximum pressure of the 1K dispense head is 2...

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    12INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsControls1K Dispense Head Sequence of Operation Manual Mode:1. The Refill button is depressed and the PC goes into a refill mode.2.The Refill Solenoid valve is energized and the Refill Valve opens. Pump press...

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    13INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsChecking Procedure1K Dispense Head checking procedure:This Procedure test the Dispense valve, Refillvalve, MLDT, Servo Valve and Pressure Transducer.1.On the Production screen put the system into the manual mo...

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    14INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1KC SystemsOverviewOperation:The A cylinder is pressurized, the A refill valve is closed, the A dispense valve is open allowing material to flow through the opened Outlet Valve. At the same time the B cylinder is exhau...

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    15INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1KC SystemsComponentsMLDT Linear Transducer:Tells the system how much material has been dispensed.Air Cylinder 22:1 Used to create the material pressure or force on the piston rod.Piston Rod oil reservoir:used DIDP oil...

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    16INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K SystemsComponentsMLDT Magnetostrictive Linear Displacement TransducerPart No. 75cc 364-650Voltage Input 24vdcVoltage Output 0-10vdcOperationAt the start of the dispense cycle the PC takes a voltage reading (style ...

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    17INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1KC SystemsComponentsAir Servo Valve: Part No. 354-515The servo controls the air pressure going to the top (down pressure) on the air cylinders. The Proportional Valve uses a 0-10vdc signal to control the air pressu...

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    18INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1KC SystemsControl PressureThe 1KC Pressure Control:The Robot Flow Command signal will change the pressure in the dispense head. The range of the robot flow command signal is from 0-4095 (0-10V). There are two types ...

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    19INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1KC SystemsManual Sequence1KC Dispense Head Sequence of Operation Manual Mode:1. The Refill button is depressed and the PC goes into a refill mode.2.Both Refill Solenoid valve is energized and the Refill Valve opens. T...

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    20INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTypes ofDispensing DispensingMethodsIngersollIngersoll--Rand Rand specializes in specializes in delivering effective delivering effective solutions for high solutions for high viscosity industrial viscosity industrial A...

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    21INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTypes ofDispensing DispensingMethodsApplications:Ingersoll-Rand Systems expertise crosses industrial and international boundaries to provide the highest levels of technology and reliability to customers who have a desir...

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    22INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTypes ofDispensing DispensingMethodsProcessesIngersoll-Rand Systems utilizes award winning technology and state-of-the-art controls to provide the most effective and reliable processes available. StreamingMaterial is ap...

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    23INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTypes ofNozzles DispensingNozzlesIngersoll-Rand uses a wide variety of nozzles to dispense a array of different materials in different applications. Specialty nozzles can be made.Shown are String dispersion, tip orient...

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    24INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BExtruding Nozzle SelectionWhen using a extruding nozzle the bead size in normally larger (10mm) then streaming. To create a 10-20mm bead with a streaming tip it would take slow robot speeds and very high pressures. Wi...

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    25INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTypes ofNozzlesDispensingAdaptorsSometimes it is necessary to install an angle offset adaptor to help make the programming easier. All of the angle adaptors have tip orientations so that they can be installed on the di...

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    26INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTypes ofTemperature DispensingConditioningTemperatureTemperature conditioning is used to create a stable environment so that the viscosity of a material remains constant throughout the day. This will improve the job to ...

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    27INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/OutputsDevice NetDevice NetIngersoll-Rand use device net as a way of communicating from the robot to the PC – The robot is the master and the PC is the slave. Also the communication from the PC to the Robot / ...

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    28INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BAnalog Output CardAnalog Input CardInput CardOutput CardBuss CouplerFusesInputs/OutputsDevice NetPC NodesThe PC uses several nodes to send inputs and outputs. The main control cabinet, each dispense J-box and pump J-bo...

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    29INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/OutputsDevice Net364-207 Device Net Communications Card (DNP)Jumper SettingsDevice Net Card Identification and SettingsDevice Net Junction Tee750-467Device Net Analog Input19 Pin Cable (J-Box to dispose head)75...

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    30INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/OutputsDevice NetPhysical DeviceNet LayoutEach DeviceNet network (bus) must be set up as a “single-file” string of devices (trunk) connected by special DeviceNet cable. Each DeviceNet network must have termin...

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    31INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/Definitions OutputsRobot Inputs (Dispense Controller Outputs) 1. Dispenser Ready: A signal indicating that the dispenser is functioning properly with no faults which prevent a normal dispense cycle. This signal r...

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    32INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/Definitions OutputsRobot Outputs (Dispense Controller Inputs) 1. Style ID Bits (1,2,4,8,16,32,64,128): An eight-bit group (binary number) output that is used to relay the style information to the dispenser. The s...

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    33INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BRobot Automatic Sequence of Operations:1. PC Sends Signal IN PROCESS offThis signal verifies that the dispense head has been reset from the last job (refilled) and is not in a purge mode. During refill the Beacon...

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    34INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BI/O TIMING CHARTSInputs/AutomaticOutputsSequence

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    35INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/AutomaticOutputsSequence This Graph shows bad TCPP ProgrammingThis Graph shows a normal TCPP Programming. Can you find the glitch?

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    36INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/Robot I/0 Outputs…(I57 – I64 Spare) (In121/185 – In128/192 Spare) …N10:I56 / N12:I56 diSLXFaultBit8 Disp X Fault Data Bit 8 In120 / In184 N10:I55 / N12:I55 diSLXFaultBit7 Disp X Fault Data Bit 7 In119 / I...

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    37INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BGM RS4 I/O: Dispense controller digital outputs (Channel 82 node 10 / 12)…(O61 – O64 Spare) (Out 125/189 – Out 128/192 Spare) …N10:O60 / N12:O60aoSLXBeadShp Disp X Bead Shaping Command Bit 2048 Out124 / Out188...

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    38INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/Configuring OutputsThe Robot I/O Device Net Variables to PCThese Values should be entered so that the Robot can talk to the PC.Communication Setup (Menu/I-O/TYPE{F1}/0{next page}/DEVICE NETRack 81 = PLC Controll...

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    39INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/Configuring OutputsThe Robot I/O Robot I/O Device net Information3. DeviceNet Board Setup and Configuration3.1. Configuring and Connecting the DeviceNet Interface DaughterboardsBefore you can connect the DeviceNe...

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    40INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/Configuring OutputsThe Robot I/O Table 3.2. DeviceNet Board Detail Screen ItemsFor slave operation, in which the R-J3iB controller acts a slave to an external master, this specifies the size of the input to the m...

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    41INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/Configuring OutputsThe Robot I/O Procedure 3.1. Configuring and Connecting DeviceNet Interface Daughterboards1.Press MENUS.2.Select I/O.3.Press F1, [TYPE].4.Select DeviceNet. You will see a screen similar to the ...

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    42INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BInputs/Configuring OutputsThe Robot I/O The Analog Values are set up as a Group BCDB bit. Menu/ IO/GroupThe style bits are set up using a eight (8) group selectionThe Analog bits are set up using a 12 group selectionFan...

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    43INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BIf the dispense path is very simple and straight direct voltage is normally used. Any voltage from 0-10v (0-4095) can be used to achieve the bead size. However if the dispense path is more complicated (see diagraph b...

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    44INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPP Tool Center Point PredictThis approach requires the most complex and costly equipment but has paid for itself by making dispense robot programming less of an art. This approach was developed solely for the purpose...

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    45INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPRobot ProgrammingEnd of Arm Tool TCPEnd-of-arm tool TCP must be set up prior to dispensing material, the tool center point must be moved from the sixth axis faceplate to the tip of the tool. Use the most accurate m...

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    46INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPMotion PlanningMotion PlanningIt is very important to correctly program the path if TCPP is being used. Themotion should be smooth and not jerky. Try to use the 4th, 5th and 6th axes as Littleas possible. When th...

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    47INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPMotion PlanningMotion PlanningThe Process of doing a corner is very simple with TCPP. Just put a point in the corner and a lead in and lead out point about 1.5 inches (3.81 centimeter) from the corner point. The ...

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    48INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPDispenserI/OSetting Up Dispenser I/O.The next step is understanding the associated data fields in the Fanuc controller thatare associated with dispensing.a.The Menu-/1/O-(type) dispenser. b.The Inputs and outputs th...

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    49INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPTuning the DispenserTuning the dispense equipment1.The first step in this process it to complete the path program. It is essential to know the robot speed. All of the adjustments for TCPP must be done at the normal...

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    50INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPSeal SchedulesSeal Schedules1.The Seal Schedules can be accessed by depressing the DATA button and then F1 Seal Schedules. 2.This is where the system can be set up for direct voltage or TCPP Bead Width calibration...

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    51INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPSeal SchedulesSeal Schedules1.Under The dispense style depress F2 for the LISTINGS of the body styles. Another screen will show some of the specific adjustable information for each individual body styles.DATA Seal ...

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    52INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPSeal SchedulesSeal SchedulesContinued:DATA Seal SchedE1Variable Orifice System 1 Schedule # 1 2 Flow type: TCPP Bead Width 3 Flow model: LINEAR 4 Flow rate: ...

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    53INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPDispenser SetupDispense Equipment TCPP SetupThis screen is under MENU/SETUP/DISPENSORThese set of variables Setup the TCPP bead size requirements.Some of the newer fields will ask for the robot speed. This would be...

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    54INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPDispenser SetupDispense Equipment TCPP SetupThese set of variables tune the TCPP variables into the dispense equipment. These arecalibrations variables used to tune the dispense bead into the required bead size.Set...

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    55INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPEquipmentDelayFinding the Equipment Delay.One of the first requirements of dispensing is to find the equipment delay. The only way that this can be achieved it to run a specific program and change the equipment ant...

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    56INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPEquipmentDelayFinding the Equipment Delay.Use seal schedule #30 and verify that the correct be size is set up in the DATA/ Seal Schedule and that the flow type is TCPP bead width.In MENU/SETUP/DISPENSER make the fol...

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    57INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPGun On-OffDelayAdjusting the Gun On-Off DelayUse seal schedule #30 and verify that the correct be size is set up in the DATA/ SealSchedule and that the flow type is TCPP bead width.1.Verify that the equipment delay ...

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    58INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPPRunning thePathRunning the Dispense pathThe TCPP variables have been defined. They just need to be transferred to the sealschedule that is being used for the dispense bead path.a.Go to the listing for seal schedule...

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    59INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BRobotProgrammingPayloadRobot MotionIf the robot motion is not smooth some additional settings may be required.Listed below are some variables that have helped programmers set up the robots andtune in the TCPP values. T...

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    60INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K & KCFault RecoveryIf a fault is on it will be shown with a red light. The setup screen determines if the fault is a Major or MinorNote this picture shows 4 faults 3 Major and 1 Minor.This a record of the faults...

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    61INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1. Replace tip and Purge.2, Change Material and Purge3, Check and reset pump pressure4. Check Temperature system and reset the material temperature.5. Reset Scaling and Batchcompensation to 1.6. Reset Variables in...

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    62INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1. Autostream software is operating correctly. The robot needs to send the robot Style bit.1. The robot did not send the Robot Style bit and the Job was Ignored.No Material DispensedNO Fault1. Look at the I/O device ...

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    63INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K & KCFault RecoveryReduce Feed Pump pressure to be at or lower than the Dispense Pressure.Feed Pump pressure is too high.Bead is Too Large at the Start of the DispenseClean out the Air Section and replace Quad Ri...

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    64INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K & KCFault Recovery•Check the pressure gauge for an abnormally high system pressure.High Water Temperature Fault is present•Verify that there is water flow through any tubing and hose Correct any pinched line...

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    65INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev B1K & KCFault RecoveryThe elevator cylinder piston O-rings are leaking and should be changed.Elevator not going up (leaking air from exhaust)Air in Foot Valve – Open bleeder valve on Foot Valve and run pump until ...

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    66INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPP Job Flow ChartCell Controllersends style startsignal (MainLine)Does the Robot havemore then 1 equipmentRun a JOB asdispense TRUEInstall the bodyvolume style bit inthe details of thejobCreate a Proces...

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    67INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BCREATING A JOB:1.Depress SELECT on the teach pendent2.Using the F buttons depress Create3.Give the job a name using the F buttons and press enter to accept the name.4.Using the F buttons select details.5.Cursor down to ...

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    68INGERSOLL-RAND © 2005 ALL RIGHTS RESERVEDJDS402 Robot Programming Rev BTCPP Extra InfoTo Look a the teach pendent using a remote computer:1.On the remote computer choose start and run.2.Type “telnet” and enter3.A dos window will open and type “open xx.xx.xx.xxThe xx.xx...

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