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Kawasaki Robot Controlle
r
E Series
Arc Welding
Operation Manual
Kawasaki Heavy Industries, Ltd.
90203－1036DEA
E Series Controller
Kawasaki Robot Arc Welding Operation Manual
PREFACE
This manual describes operating instructions for arc welding specification of the Kawasaki Robot
Controller E series. This manual is supplemental for standard Operation Manual. Read
thoroughly the Safety Manual and other relevant manuals such as the Connection and Installation
Manual for arc weld robot controlled via E series controller. Once the contents of these manuals
are thoroughly read and understood the robot can be used.
This manual provides as much detailed information as possible on the standard operating methods
for arc welding specification of the Kawasaki robot. However, not every possible operation,
condition or situation that should be avoided can be described in full. Therefore, should any
unexplained questions or problems arise during robot operation, please contact Kawasaki Machine
Systems. Refer to the contact information listed on the rear cover of this manual for the nearest
Kawasaki Machine Systems office.
The explanations in this manual include information on optional functions, but depending on the
specification of each unit, not every optional function detailed here may be included with the robot.
Also, note that figures given here may differ partially from actual screens.
1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damage, and/or problems relating
to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching, maintenance
or inspection of the robot attend the necessary education/training course(s) prepared by
Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is reinstalled
or moved to a different side or sold off to a different use, attach this manual to the robot without
fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2011 Kawasaki Heavy Industries Ltd. All rights reserved.
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E Series Controller
Kawasaki Robot Arc Welding Operation Manual
SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.
DANGER
！
Failure to comply with indicated matters can result in
imminent injury or death.
Failure to comply with indicated matters may possibly lead to
injury or death.
！
WARNING
！
Failure to comply with indicated matters may lead to physical
injury and/or mechanical damage.
CAUTION
[ NOTE ]
Denotes precautions regarding robot specification,
handling, teaching, operation and maintenance.
1. The accuracy and effectiveness of the diagrams, procedures, and detail
explanations given in this manual cannot be confirmed with absolute
certainty. Accordingly, it is necessary to give one’s fullest attention when
using this manual to perform any work. Should any unexplained questions
or problems arise, please contact Kawasaki Machine Systems.
2. Safety related contents described in this manual appl
y
to each individual work
and not to all robot work. In order to perform every work in safety, read
and fully understand the safety manual, all pertinent laws, regulations and
related materials as well as all the safety explanation described in each
chapter, and prepare safety measures suitable for actual work.
！
WARNING
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E Series Controller
Kawasaki Robot Arc Welding Operation Manual
INTRODUCTORY NOTES
1. HARDWARE KEYS AND SWITCHES (BUTTON)
E series controller provides hardware keys and switches on the operation panel and the teach pendant
for various kinds of operations. In this manual the names of the hardware keys and switches are
enclosed with a square as follows. The terms “key” or “switch” which should follow the relevant
names are sometimes omitted for simpler expression. When pressing two or more keys at the same
time, the keys are indicated by “+” as shown in the example below.
EXAMPLES
TEACH/REPEAT: indicates the mode switch “TEACH/REPEAT” on the operation panel.
A+MENU: indicates pressing and holding down A then pressing MENU.
2. SOFTWARE KEYS AND SWITCHES
E series controller provides softw are keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this manual,
the names of software keys and switches are enclosed by “< >” parentheses. The terms “key” or
“switch” which should follow the relevant names are sometimes omitted for simpler expression.
EXAMPLES
<ENTER>: expresses an “ENTER” key that appears on the teach pendant screen.
<NEXT PAGE>: expresses a “NEXT PAGE” key on the teach pendant screen.
3. SELECTION ITEMS
Very often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items are enclosed in brackets [XXX].
EXAMPLES
[Auxiliary Function]: Expresses the item “Auxiliary Function” in a menu. To select it, move the
cursor to the relevant item by the arrow keys, and press the ↵ key. For
detailed description, this procedure should be described every time, but “select
[XXX] item” will be used instead for simpler expression.
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E Series Controller
Kawasaki Robot Arc Welding Operation Manual
CONTENTS
1.0 Overview of Arc Welding Control·······················································································1-1
1.1 Configuration of Arc Welding Robot System ·····································································1-1
1.2 E Controller Specifications for Arc Welding·······································································1-2
2.0 Hardware Keys on Teach Pendant·······················································································2-1
2.1 Overview of Teach Pendant·································································································2-1
2.2 Hardware Keys on Teach Pendant·······················································································2-2
3.0 Instructions for Operating Screen on Teach Pendant···························································3-1
3.1 Status Area····························································································································3-2
3.2 F keys (Function Keys)·········································································································3-3
3.3 Monitor Screen ·····················································································································3-4
3.3.1 PC Program···························································································································3-4
3.3.2 Arc Status Screen··················································································································3-5
3.3.3 Step Information (Auxiliary Data) Screen···········································································3-6
4.0 Manual Operation of Robot··································································································4-1
4.1 Manual Operation of Robot··································································································4-1
4.1.1 Aligning Operation···············································································································4-1
4.1.2 Setting for Keeping Base +Z Direction················································································4-3
4.2 Inching Operation for Weld Wire ························································································4-4
4.3 ON/OFF Operation for Supplying Shield Gas·····································································4-4
5.0 Teaching································································································································5-1
5.1 Overview of Teaching Operation·························································································5-2
5.1.1 Basic Flow of Teaching Operation·······················································································5-2
5.1.2 Type of Teaching Points and Auxiliary Data·······································································5-3
5.1.3 Weld Condition·····················································································································5-4
5.1.3.1 How to Set Weld Condition·································································································5-4
5.1.3.2 Types of Weld Conditions····································································································5-5
5.2 Teaching for Arc Welding····································································································5-6
5.2.1 Creating a Program Sheet·····································································································5-6
5.2.2 Preparation for Teaching······································································································5-7
5.2.3 Configuration of Teach Screen·····························································································5-8
5.2.4 Teaching Operation············································································································5-10
5.3 Setting Other Auxiliary Data······························································································5-17
5.3.1 Setting Option Switches ·····································································································5-18
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Kawasaki Robot Arc Welding Operation Manual
5.3.2 Setting Weld Conditions·····································································································5-18
5.3.3 Setting Special Conditions··································································································5-18
5.4 Real Time Weld Condition Modification Function···························································5-19
6.0 Repeat Operation··················································································································6-1
6.1 Real Time Weld Condition Modification Function·····························································6-1
7.0 Program Modification···········································································································7-1
7.1 Program Editing Screen········································································································7-1
7.1.1 Step Modification on Program Edit screen··········································································7-1
7.1.1.1 Pose Data and Auxiliary Data Modification········································································7-1
7.2 Online Editing Function ·······································································································7-4
7.2.1 Screens that Can Use Online Editing Function····································································7-4
7.2.2 Functions Used in Online editing Screen·············································································7-4
8.0 Auxiliary Functions··············································································································8-1
8.1 Overview of Auxiliary Function ··························································································8-1
8.2 Auxiliary Function List·········································································································8-2
9.0 Touch Sensing Function (Option)························································································9-1
9.1 Overview of Touch Sensing Function··················································································9-1
9.1.1 Features of Touch Sensing Option Function········································································9-1
9.1.2 Sensing Patterns for Compensation of Workpiece Deviation·············································9-2
9.2 Wire Check Function··········································································································9-10
9.2.1 Teaching for Wire Check Function····················································································9-10
9.2.2 Wire Check Function at Repeat Operation········································································9-13
9.3 Workpiece Detection Function···························································································9-14
9.3.1 Teaching for Workpiece Detection Function·····································································9-14
9.3.2 Workpiece Detection Function at Repeat Operation·························································9-17
9.4 Compensation Function for Workpiece Deviation····························································9-18
9.4.1 Combination of Sensing Patterns·······················································································9-18
9.4.2 Teaching- Compensation Function for Workpiece Deviation- 1
(Teaching for Each Sensing Pattern)··················································································9-21
9.4.3 Teaching- Compensation Function for Workpiece Deviation- 2
(Teaching for Combination of Sensing Patterns)·······························································9-26
9.4.4 Compensation for Workpiece Deviation at Repeat Operation··········································9-32
9.4.5 Continuation and Reset of Workpiece Deviation Compensation······································9-33
9.4.5.1 Continuation and Reset of Compensation··········································································9-33
9.4.5.2 Cases of Continuing/Resetting Compensation···································································9-35
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Kawasaki Robot Arc Welding Operation Manual
9.5 Precautions on Teaching·····································································································9-36
9.6 Error Handling when Operating Touch Sensing Function················································9-39
9.6.1 Error Message List··············································································································9-39
9.6.2 Errors and Countermeasures ······························································································9-40
10.0 Special Pattern Weaving Function (Option)······································································10-1
10.1 Overview of Special Pattern Weaving···············································································10-1
10.1.1 Special Pattern Weaving·····································································································10-1
10.1.2 Pendulum Weaving ············································································································10-3
10.1.3 Weld Current/ Weld Voltage Boosts··················································································10-3
10.1.4 Flow Chart for Using Special Pattern Weaving Function·················································10-4
10.2 Standard Weaving Patterns Registered for Robot······························································10-5
10.3 Teaching Operation for Special Pattern Weaving····························································10-11
10.4 Creating a New Weaving Pattern·····················································································10-12
10.4.1 Coordinates System and Parameters when Creating Weaving Pattern···························10-12
10.4.2 Creating Weaving Patterns·······························································································10-14
11.0 Servo Torch Function (Option)··························································································11-1
11.1 Overview of Servo Torch Function····················································································11-1
11.2 Procedure for Setting Servo Torch as External Axis·························································11-2
11.3 Servo Torch Specification··································································································11-3
11.3.1 Auxiliary Functions for Servo Torch·················································································11-3
11.3.2 Differences: Servo Torch Spec. vs. Standard Arc Spec.····················································11-3
11.4 Error Handling when Operating Servo Torch Function····················································11-4
11.4.1 Error Message List··············································································································11-4
11.4.2 Errors and Countermeasures ······························································································11-4
12.0 Error Message for Arc Weld Specification········································································12-1
12.1 Error Message List··············································································································12-2
12.2 Errors and Countermeasures ······························································································12-3
Appendix 1.0 Program Sheet ···········································································································A-1
Appendix 2.0 Weld Database···········································································································A-3
Appendix 3.0 Pattern Example of Special Pattern Weaving (List)·················································A-7
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E Series Controller 1. Overview of Arc Welding Control
Kawasaki Robot Arc Welding Operation Manual
1.0 OVERVIEW OF ARC WELDING CONTROL
The standard E series controller has been incorporated with control functions specific to arc
welding. With these functions, the robot can be programmed to work flexibly and efficiently
with weld machines to produce variety of high quality welds.
1.1 CONFIGURATION OF ARC WELDING ROBOT SYSTEM
Arc welding robot system consists mainly of the following components. See the figure below.
1. Robot for arc welding (RA series robot, etc.)
2. E Series Controller for arc welding
3. Arc welding torch
4. Other devices for arc welding (weld power supply, wire feeder, gas supplying unit, cable, etc.)
5. Other optional devices (torch cleaner, etc.)
This manual mainly focuses on No.2 above, regarding items relating to E Series Controller for arc
welding. For details about other materials, see the standard operation manual, specification
sheets, etc.
Wire feeder
E Series Controller
for arc welding
Robot main body
for arc welding
Weld power supply
A
rc welding torch
1-1
E Series Controller 1. Overview of Arc Welding Control
Kawasaki Robot Arc Welding Operation Manual
1.2 E CONTROLLER SPECIFICATIONS FOR ARC WELDING
Specifications for arc welding control are as follows. For details about other standard
specifications, refer to the Operation Manual for E series controller.
1. Necessary boards: Arc welding interface board (1TW/1GN boards)
Optional daughter boards (when using optional functions)
2. Arc welding control functions: Command of arc welding voltage/current to the weld power
supply, motor control for wire feed (including inching/retract),
gas supply ON/OFF, weld stuck detection
3. Optional control function: Touch sensing, special pattern weaving, etc.
1-2
E Series Controller 2. Hardware Keys on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
2.0 HARDWARE KEYS ON TEACH PENDANT
This chapter describes hardware keys on teach pendant specially for arc welding specification.
For details about other standard keys, refer to Operation Manual for E series controller- 2.4
Switches on Teach Pendant and Functions of Hardware Keys.
2.1 OVERVIEW OF TEACH PENDANT
Figure 2.1 shows the arrangement of the hardware keys on arc welding teach pendant.
Figure 2.1
2-1
E Series Controller 2. Hardware Keys on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
2.2 HARDWARE KEYS ON TEACH PENDANT
This chapter describes the function of each of the hardware keys for arc welding closed by
in Figure 2.1
Keys Function
Feeds weld wire when pressed. See 4.2 Inching Operation for Weld
Wire for more details. Pressing F key <Wire Inching> changes the speed
at which wire is fed.
Manually turns ON shield gas supply when pressing A + GAS ON. The
gas is turned ON only while the key is pressed.
Retracts weld wire when pressed. The wire is retracted only while the
key is pressed. See 4.2 Inching Operation for Weld Wire for more
details. Pressing F key <Wire Inching> changes the speed at which wire
is pulled back. Pressing A + CND.CHG. displays Real Time Condition
Modify screen in C area.
A + WELD ON/OFF selects weld ON and OFF during repeat/check
operations.
A + INSTR. selects the instructions column under “Mtd” on block
teaching screen. See 5.2.3 Configuration of Teach Screen for picture.
A + CND.NUM. selects the weld condition number column on block
teaching screen. See 5.2.3 Configuration of Teach Screen for picture.
A + WELD CND. selects the weld conditions (Spd Amp Vlt Tmr Amp
Vlt) set for the weld condition number on block teaching screen. See
5.2.3 Configuration of Teach Screen for picture.
A + SPEC.CND. selects the special condition column on block teaching
screen. See 5.2.3 Configuration of Teach Screen for picture.
A + OPTION selects the option switch column on block teaching screen.
See 5.2.3 Configuration of Teach Screen for picture.
A + JT6 +/- executes 45° align operation while in base mode.
A + JT7 +/- executes 90° align operation while in base mode.
2-2
E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
3.0 INSTRUCTIONS FOR OPERATING SCREEN ON TEACH PENDANT
This chapter describes the screens on the teach pendant used for operating the arc welding
functions. For details about other standard operating screens, the functions available on each
screen and their operation procedures refer to Operation Manual for E series controller-2.4
Switches on Teach Pendant and Functions of Hardware Keys.
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E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
3.1 STATUS AREA
When weld is set ON by pressing A + WELD ON/OFF, the following icon is displayed in the
status (F) area as shown below.
When Weld ON:
When Weld OFF:
Weld ON: Icon lights up
Weld OFF :< Arc OFF>
Weld ON:<Arc ON>
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E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
3.2 F KEYS (FUNCTION KEYS)
The chart below shows the functions of the arc weld specification F keys (shown as 1 to 3 in
figure below), displayed on teach mode screen. For other F keys, see the Operation Manual for
E series controller 2.6 Operation Keys on Teach Pendant Screen.
When pressed with A key
No.
Operation
key
Functions
Operation Functions
1 Displays the arc status
monitor (see 3.3.2 for details
on arc status monitor).
When weld is ON, the icon
lights up.
Displays the arc status
monitor (see 3.3.2 for details
on arc status monitor).
When weld is ON, the icon
lights up.
2 Displays the real time
condition editing screen. For
details on real time condition
editing screen, see 5.4 and 6.1.
Displays the real time
condition editing screen. For
details on real time condition
editing screen, see 5.4 and 6.1.
3 Sets the speed to feed or
retract the wire via
Wire Inching and Wire
Retract. The speed changes
in 3 levels from 1 to 3 every
time the key is pressed.
Sets the speed to feed or
retract the wire via
Wire Inching and Wire
Retract. The speed changes
in 3 levels from 1 to 3 every
time the key is pressed.
2
1
3
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E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
3.3 MONITOR SCREEN
In arc welding specification, the items below are added to the standard specification menu.
1. PC program (Monitor function no. 27)
2. Arc status (Monitor function no. 82)
3. Step information (Monitor function no. 83)
Figure 3.1
For details on other monitor functions on the menu, see the Operation Manual for E series
controller 2.9 Monitor Screen.
3.3.1 PC PROGRAM
Selecting [PC Program] in Figure 3.1 displays the screen in C area similar to Figure 3.1
Figure 3.2
This screen displays the data of up to five PC programs.
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E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
3.3.2 ARC STATUS SCREEN
Selecting [Arc Status] in the screen shown in Figure 3.1 displays current robot status, arc weld
conditions, etc. as shown in Figure 3.3.
Figure 3.3
The following items are shown highlighted when the I/O signal is ON.
Input Signal: Current Detect, Pole Stuck, Torch Interfere, Wire Touch, Wire Stuck
Output Signal: Arc ON, Wire Inching*, Wire Retract*, Gas ON, Touch Sensor ON, Weld ON
In Figure 3.3, Torch Interfere and Weld ON are ON.
NOTE* For Wire Inching or Wire Retract, only one output signal can be ON. They cannot be
ON simultaneously.
In Curr. Comm. and Volt. Comm., the current command values are displayed.
Current Command: 0.00 - 15.00 V
Voltage Command: 0.00 - 15.00 V
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E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
3.3.3 STEP INFORMATION (AUXILIARY DATA) SCREEN
Selecting [Step (Aux)] in Figure 3.1 displays the screen in C area as shown in Figure 3.4.
Figure 3.4
This screen displays all the auxiliary data for the selected step in the selected program. During
repeat operation, etc., when a step moves forward, the contents of the currently running step are
displayed.
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E Series Controller 4. Manual Operation of Robot
Kawasaki Robot Arc Welding Operation Manual
4.0 MANUAL OPERATION OF ROBOT
When wire feeder or shield gas supplying unit are connected to E series controller, the teach
pendant can be used to manually inch/retract weld wire or turn ON/OFF gas supply in addition to
the normal robot operations by teach pendant. For details about connecting devices, see
Installation and Connection Manual for arc welding E series controller.
4.1 MANUAL OPERATION OF ROBOT
Same as standard specification robots, the arc welding robot can be driven manually in the
desired mode: joint, base coordinate based, or tool coordinate based. For more details, see
Operation Manual for E series controller- 4.0 Manual Operation of Robot.
This section describes the align operation, a function useful for arc weld teaching. Instructions
are also given for setting the robot installation posture in Aux. Function 0505 Robot Installation
Posture. In addition, the fixing of the +Z base axis in vertical direction regardless of the posture
set in Aux. 0505 is explained in detail.
4.1.1 ALIGNING OPERATION
Aligning function rotates the tool to make the Z axis of the tool coordinates parallel to the nearest
base coordinate axis during teaching. This is convenient for aligning the tool direction with the
Z axis of the base coordinates (especially when teaching downward welds) before teaching a weld
line.
RX and RY rotate → parallel to Z axis.
Base coordinate
system
1. Press INTER and select base mode.
[ NOTE ]
Aligning operation is not possible in joint or tool modes.
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E Series Controller 4. Manual Operation of Robot
Kawasaki Robot Arc Welding Operation Manual
2. While pressing down the TRIGGER, press A + JT6 +/- for aligning at 45°, and A + JT7 +/-
for aligning at 90°. For 90° alignment, robot arm stops and align is complete when Z axis of
the tool becomes parallel to the base coordinates Z axis.
Y
Z
X
Base coordinates
X
Y
Z
45°
45°
Base coordinates
s
y
ste
m
system
45° alignment 90° alignment
[ NOTE ]
Aligning operation can also be used for aligning the tool coordinates with
the base coordinates X or Y axes. Before aligning, move the tool near the
desired base coordinates axis and then execute the procedure described
above.
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E Series Controller 4. Manual Operation of Robot
Kawasaki Robot Arc Welding Operation Manual
4.1.2 SETTING FOR KEEPING BASE +Z DIRECTION
The +Z direction of the base coordinate motion can be set perpendicular upwards during teaching,
once the actual installation posture is made to match the posture set in the controller.
The direction of robot’s base coordinates is set as shown in the figure below. However, the
value of the base coordinates must have O, A, and T set to 0(zero) in Aux. Function 0506 Base
Coordinates.
Floor Ceiling
Wall
Wall
2
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