KUKA robot electric servo welding clamp configuration and force establishment process V4.21

Catalog elements that are not included in the SGB option package can be added individually via the catalog management. The catalog element "VW_SGB" must be added. Insert the appropriate pliers via File → Catalog Management

Insert the pliers from the catalog into your project by dragging and dropping. The name usually corresponds to the name on the (note the nameplate)

Depending on the configuration, the clamp is suspended from the flange in a unit configuration.

The circuit of the robot clamp is as follows:

Configure welding gun

Several signals from the welding gun must be configured. Double-click on the tongs and select the tab "ServoGun" in the middle display window.

The following signals can be used: Change:

Force activation: If no KUKA force sensor is used, remove the hook

Select the type of pliers: C-gun or X-gun

Compensation Type: If using pneumatic A compensation, select "Air compensation" and configure the correct output indicator for "Compensation cylinder 1" under "Output".

Enter the maximum clamping force

Enter the maximum consumption

Inserting the VW welding controller into a WorkVisual project

If KOP is installed, the welding timers are located in the catalog under the "Options" tab. Drag and drop the appropriate welding timer into your project.

By default, the following timers are available and must be used depending on the hardware available in your system:

VW: specially designed timer for VW based on PSI6xxx.201.

In this timer, the EA is already preset for the first timer configured in the project and no longer needs to be adjusted. If multiple timers are implemented in a project, the EA area must be adjusted manually.

The timer can be used with all welding timers that have an interface that complies with Volkswagen Group standards.

Custom Timer: A "null" timer available to the customer. If the previously described timers are not used, a custom timer must be configured by the customer.

The welding timer does not have to be explicitly connected, but must be set in the corresponding configuration of the pliers, as shown in subsequent lessons of this document.

The timer must then be assigned to the pliers. Double-click on the pliers and select the ServoGun tab in the middle display window. Select the appropriate welding timer for the selected pliers by selecting the field "Welding Timer Index".

The bus connection for Profinet must still be configured in the bus structure. The following figure shows the overall project structure as an example. Depending on the components used, the structure may differ from this representation and is only used as an indication.

Background Process - Configuring I/O

Select ServoGun Editor in the top menu

-Scroll down in the ServoGun Editor

- In the menu "PLC output background processing", configure the output

Go to bed

- If all necessary settings have been made in WoV, you can generate the code by clicking the corresponding button. After successful code generation (pay attention to the message window), you can transfer the project to the controller via the "Install" button.

After successfully installing the project, the ServoGun options will also be installed on the controller, which can be checked under Help → Information → Register Options.

KUKA robot configuration electric servo welding gun, using software plug-in "SERVOGUN.B"

Motor drive schematic: X-type welding clamp

C-type welding tongs

Commonly used control variables of KUKA robots:

Welding point: PTP VB=100% VE=0% ACC=100% RobWzg=1 Base=1 SPSTrig=5[1/100s]P Track point….. 2: SERVOZANGE 1 Schweissen Progmnummer= 99 Punktnummer=5154 FahrzeugTyp= 60 Offset= 1[1/10mm] achIn= Auto Ausgleich=MITTELBedingung=EIN… VW_SGB_CONFIG_SPOT_CHECK(1,#EQUALIZING) -- Checks if the balancing type is correct VW_SGB_SPOT_V(TRUE,#SG_PTP,P10,1,99,5154,60,1,TRUE,0,ServoGun[1].CompType,#MEDIUM,0,0 ,0) Advance welding controller communication PTPP10 execution trajectory point $ADVANCE=3 VW_SGB_SPOT_MAIN(TRUE,#SG_PTP,P10,1,99,5154,60,1,TRUE,0,ServoGun[1].CompType,#MEDIUM, 0,0,0) Execute clamp welding function TRIGGER WHEN DISTANCE=1 DELAY=-50 DOSPS_TRIG(12) PRIO=-1 Execute SPS program PTP P10 Execute track point

KUKA robot control force function: ACTIVATE_FORCE_MODE((6+SG_ExtaxActive), FORCE, SGL_CalcPartPos(SG_CurrentCmd),SGEQ_AFM_ConstSpeedUser)

The process of establishing force:

TeachIn = Auto: TeachIn • Auto: Automatic: Use the workpiece thickness determined by the teach-in process. • Manual: Manual: The workpiece thickness must be specified inline Ausgleich = MITTEL Balance control OFF: No balance control SCHWACH Weak: For soft workpieces that can be bent over 3 mm even with little force (hand force). MITTEL Medium: For medium-sized workpieces of 1-3 mm that can be bent with little force (hand force). STARK Strong: For hard workpieces that only bend with strong force (cannot be bent by hand). INDIVIDUELL Individual: The value can be adjusted to the individual case. For this purpose, additional fields are displayed.

The communication connection of the robot's welding controller has the input point of the force SG_Force_WT_S[1]=793, the start byte SG_Force_WT_E[1]=800, and the end byte SG_GunForce= SG_PointForces[1]. The force value is transmitted and the working force value is fed into the system function 'ACTIVATE_FORCE_MODE' to realize the force control.

ACTIVATE_FORCE_MODE(AXIS_NO, TARGET_FORCE, PART_POSITION, CONST_SPEED_USER) Syntax Description Element Description AXIS_NR Type: INT Transfer type: IN Parameter Axis number 1 ... MAX_AXIS TARGET_FORCE Type: INT, Unit: N Transfer type: IN Parameter Target force PART_POSITION Type: REAL Transfer type: IN Parameter Component position in mm or ° relative to the output --- Position of the clamp to be closed with force CONST_SPEED_USER Type: REAL Transfer type: IN Parameter Reduced constant speed in mm/s or °/s relative to the output Program Example DEF SPOT() Calculate part thickness plus part tolerance EG_CONTACT_DIST = EG_WELD_TOL_N[EG_EXTAX_ACTIVE] - EG_THICKNESS ; Turn on force control ACTIVATE_FORCE_MODE((6 +EG_EXTAX_ACTIVE), TARGET_FORCE, EG_CONTACT_DIST, EG_CONST_SPEED_USER) $VEL_EXTAX[EG_EXTAX_ACTIVE] = CONST_SPEED External axis speed PTPP_PART C_PTP Notice $FORCE[x] can only be used to switch off force control and modify the target force when force control is active. The target force enforced with ACTIVATE_FORCE_MODE() is activated in subsequent motion blocks. If a separate constant speed is not required, CONST_SPEED_USER can be set to 0.0. In this case, the constant speed is calculated using the configuration parameters. In KSS 8.3.12 and later, forced control mode can no longer be activated using $FORCE[x] (1) Correct programming of force control mode ------------------------end---------------------------------- Review editor: Li Qian