Post on 09-Feb-2018
Robotic Arc Welding Interfacing
Josh Williamson
Fronius USA LLC
6797 Fronius Drive
Portage, IN 46368
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Presentation Topics
/ What is a Robotic Interface???
/ Interface History
/ Communication Protocols
/ Smart Interfaces
/ Overview of a robotic shipbuilding project.
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The connection and interaction between the robot, the welding hardware, and the user.
What is a Robotic Interface???
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The connection and interaction between the robot, the welding hardware, and the user. Robot
Controller and Teach Pendant
Robot Technician
Welding Power
Source & Interface
Robot and Positioning Equipment
What is a Robotic Interface
Interface Basic Signals
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Presentation Topics
/ What is a robotic interface???
/ Interface History
/ Communication Protocols
/ Smart Interfaces
/ Overview of a robotic shipbuilding project.
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Interface History
1982 Motoman System
General Interface trends
Interfaces progression over the last 25 years:
• Relays and discrete i/o
• Discrete i/o with 2 or 3 analog channels
• Increased functionality and process control
• Improved user interfaces (4 digits Windows type indefinite)
• Increased communication interfaces
(16 in/out 1024 signals, field buses, Ethernet)
• Increased computational power (8 kb 13 Mb)
• Easier to setup and diagnose
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Interface History
Early 80’s Motoman RX Controller Current Motoman DX Controller
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Interface History
ABB S1 Controller 1974-1982 ABB IRC5 Controller
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Presentation Topics
/ What is a robotic interface???
/ Interface History
/ Communication Protocols
/ Smart Interfaces
/ Overview of a robotic shipbuilding project.
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Interface Communication Protocols
EtherNet IP
IP Industrial Protocol
Developed by Rockwell 1990
Based on Common Industrial Protocol (CIP)
Ethernet (Modbus) UDP
Uses ethernet cables
Developed in 1979
No Royalty-Fee
Discrete I/O
Troubleshooting physical signals
Time consuming setup
Additional i/o boards sometimes needed
Profi-Bus
Developed 1989 in Germany
Software necessary to create network
GSD file (general station description)
DeviceNet
Developed by Rockwell
Based on CIP
Noise Sensitive
EDS file (electronic data sheet)
Profi-Net
Maintained by a community (PI)
Energy savings
GSD file (general station description)
Wireless
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Simple Interface
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Ethernet Interface BitMap
Troubleshooting (error codes)
EFD xxx Error with the wire feed system, refer to wire feeder error codes for more details Err 049, 051, and 052 Error detected in mains power input (phase missing or voltage too low/high). Check mains. Err PE Voltage detected on earth ground. Check for isolation between welding ground points and earth ground points. No H2O Error with the coolant system, check cooler for operation and system for good flow. STOP Communication or E-Stop condition with robot. Check for Robot Ready and Error Reset signals from robot.
Weld Process • The flow rate of the shielding gas is a critical aspect of
the welding process. Too high OR too low will have a
serious impact on weld results.
• Rule of thumb for the flow rate: 10 – 12 times the
diameter in l/min of flow
- 1.2mm x 10 = 12 l/min
- 1 l/min = 2.1 CFH
- 12 l/min x 2.1 = 25 CFH
• Helium and Hydrogen require about 50% more flow
than other gases due to their lighter weights.
Correct flow rate Excessive flow rate
Gas Pressure Sensor
Manually set gas valve that reports a gas error to the weld
system when flow is too low. Only errors out for low flow
and doesn’t report specific flow information.
Digital Gas Sensor
The specific gas flow is set, regulated, and monitored
using this device. Not only is a low or high flow rate
detected, but the system also reports back specific gas
flow data.
Fronius Options
Typically, the weld system opens and closes the gas
valve. If flow monitoring is desired within the system, the
following options are available.
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Presentation Topics
/ What is a robotic interface???
/ Interface History
/ Communication Protocols
/ Smart Interfaces
/ Overview of a robotic shipbuilding project.
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Smart Interfaces
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Presentation Topics
/ What is a robotic interface???
/ Interface History
/ Communication Protocols
/ Smart Interfaces
/ Overview of a robotic shipbuilding project.
32 Fronius USA /Product Overview / 6/11/2013
Tech Support USA
Service & Application Support
Weld Testing & Development
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