Introduction to the control method of KUKA robot Volkswagen PFO laser flying welding head

PFO flight hot melt laser welding



+ BM basic machine (fuselage)

+ CAI clean air inflator

+ CT control unit

+ DPS

+ LCO laser cooling

+ MDI main distribution

+ OS part

+ PU pump module device

+ RDS recirculation drying system

+ UC user room

+ UC.LP1 user room LP1



control unit Each board communicates with CPX through the HAAS-Bus bus, and CPX interacts with the outside. Subsystem DPS, ACL, CMD control board is connected to DLC2 through -Bus, and IPUC is also connected to DLC2 through the internal CAN-Bus bus after accessing STC. Switching and emergency stop interaction interface

These three interfaces have been mentioned in the previous introduction, located in the power supply unit, connected to the CMD control board.



Dual-channel emergency stop circuit, external emergency stop button in the laser emergency stop circuit



In the figure, S1 is the internal emergency stop button of the laser (on the control panel). The external emergency stop button is connected in series to the laser emergency stop circuit. After pressing, the laser light source and water circulation stop working, but still run.

This wiring method does not affect external devices. The laser stops after pressing the emergency stop.

Dual-channel emergency stop circuit, the laser emergency stop button is on the external emergency stop circuit:



an emergency stop relay needs to be installed externally, the emergency stop button on the laser and the external emergency stop button are connected in series, and the external emergency stop relay Kx is disconnected after pressing.

The emergency stop channel is connected to Kx, and the external device can also be connected to Kx, so that no matter which emergency stop is pressed, the laser and the external device will enter the emergency stop state.



Control diagram:



Use plug-in: PFODRIVER plug-in ECAT_SYS_X44 plug-in

Robot CCU version interface X44: Bus address: 172.20.3.3 Converter device EtherNET bus address: 172.20.3.99





1 11 1 54 0 11 Program

1 Point No.

54 Image No.

0.00 0.00 0.00 1.00 3700 6.50180.00 95

1659.512939 -624.7567141170.155029 1.574618 0.620315 0.006379 0.00 0.00 0.00

------Space coordinates of the point------

The length and direction of the fixed graphics are replaced by different image numbers



Analysis of the weld bead position teaching program (teaching mode)



For automatic operation, a folio must be created from the subroutine.

A folio is a file used by the PFO driver to perform a welding task, which contains the robot coordinates and all necessary welding parameters.

To make additional parameters, the "Laser PFO Display" plug-in must be started, which can be found under "Display in Laser PF0" (Figure 2).

When the robot is executing the weld position teaching program, when the robot runs to the weld trajectory point, the weld program number, weld point number, weld graphic attributes and coordinate values ​​are recorded through the KUKA user program, and then stored in the PFO application software database.

User program using standard graphics in the software library









2: VW_PFO VIRT_PUNKT Programm=14 Punkt=7 Betriebsart = for ZIRK Adjustment = ach Template Rampe = Ende

Use arc welding

2: VW_PFO VIRT_PUNKT Programm=14 Punkt=8 Betriebsart = for PTP Adjustment = Teach Template Rampe = AUS

Use PTP point-to-point welding

3: VW_PFO VIRT_PUNKT Programm=56 Punkt=2 Betriebsart = for LIN Adjustment = Teach Template Rampe = AUS

Use LIN point-to-point welding

Welding program analysis



When the robot executes the flying welding program, the KUKA user program calls the program number of the weld pass and gives it to the PFO software. Then the PFO software sends all the weld passes and their data activated in this program number to the PFO welding head through the CAN bus. The welding head welds all the weld passes in this program number one by one.

Program - is a Folist number generated by a subroutine. At the end of recording this number is stored in the recording file name, here if it is not specified the number 99 is automatically assigned, allowing recording file numbers 1 - 99. Initialization of PFO is such a meaningless number.

Subroutine In the subroutine, all weld pattern positions and welding parameters are studied. The center point of the weld pattern is always programmed (see Figure 5).



In the first step, the laser must be focused on the component, for this the pilot laser point is positioned in the middle of the crosshairs by moving in the Z direction.

The crosshairs are switched on and off by switching the image mode on and off.

After the laser is focused, the PFO must be positioned vertically above the component.

For this purpose you can use the programming aid from Trumpf, as shown in Figure 7.

The programming aid is positioned in the middle of the crosshairs. Now rotate around the TCP until the pilot laser disappears in the hole of the programming aid.

User requests defocused weld figure in millimeters

VW_PFO PFO_Spezial Defokus Set Ueberlagerung = xx Wert Defo_mm Temp_mm/s =10

Using templates to overlay LIN or CIRK motion

The user requires the interpolation path to be covered with a template with a specified template speed (mm/s)

VW_PFO PFO_Spezial Template Ueberlagert Ueberlagerung = Template versatz Wert Defo_mm Temp_mm/s =100

VW_PFO PFO_Spezial Template Ueberlagert Ueberlagerung = Vorschub aus Wert Defo_mm Temp_mm/s =100

VW_PFO PFO_Spezial Template Ueberlagert Ueberlagerung = Template anreihen Wert Defo_mm Temp_mm/s

Different superposition methods of the LIN driving pattern are shown. The same template (full circle) was used.

Review editor: Liu Qing