OTC Robot Instruction (General)

(1)

Robotic Operations Instruction Robotic Operations Instruction

Part 1 (General Robots)

A.

A. Intro to OperationsIntro to Operations B.

B. Setting Up My RobotSetting Up My Robot 1.

1. Program AllottingProgram Allotting 2.

2. Proper StagingProper Staging 3.

3. Proper ToolsProper Tools C.

C. Running My RobotRunning My Robot 1.

1. Loading PartsLoading Parts 2.

2. Buttons GaloreButtons Galore 3.

3. Fixture QualityFixture Quality D.

D. Correcting Run ErrorsCorrecting Run Errors

Part 2 (OTC)

E.

E. Intro to ProgrammingIntro to Programming F.

F. Programmable PointsProgrammable Points 1.

1. Position PointsPosition Points

-- “P” Points“P” Points

-- “L” Points“L” Points

-- “C” Points“C” Points

-- “HP” Points“HP” Points

2.

2. Non-Position Points/CommandsNon-Position Points/Commands

-- “T” Points“T” Points

G.

G. Welding CommandsWelding Commands 1.

1. Intro to Welding CommandsIntro to Welding Commands 2.

2. “AS” – “AS” – _{Arc Start}_{Arc Start}

-- VoltsVolts

-- Amps / IPM (Wire)Amps / IPM (Wire)

-- Torch SpeedTorch Speed 3.

3. “AE” – “AE” – _{Arc End}_{Arc End}

-- VoltsVolts

-- Amps / IPM (Wire)Amps / IPM (Wire)

-- Crater TimeCrater Time

-- Post FlowPost Flow 4.

4. “WS” – “WS” – _{Weave Start}_{Weave Start}

-- Amplitude (Y1, Y2)Amplitude (Y1, Y2)

-- FrequencyFrequency

-- ¼ , Center, ¾ Stops¼ , Center, ¾ Stops 5.

(2)

PART 1 (General Robots)

Intro to Operations Intro to Operations

Welcome to the world of Robotic Welding. Robots have been used in manufacturing for years, and are Welcome to the world of Robotic Welding. Robots have been used in manufacturing for years, and are the future of most production based companies. Th

the future of most production based companies. The task of running a robot, e task of running a robot, while it may seem simple, can bewhile it may seem simple, can be anything but, at times. A lot of

anything but, at times. A lot of the fundamentals from hand welding can easily be the fundamentals from hand welding can easily be applied to running a robot.applied to running a robot. Similarities include, blueprint reading, staging your area, fixturing, qualit

Similarities include, blueprint reading, staging your area, fixturing, qualit y, and safety to name a fey, and safety to name a few. We willw. We will go into more details soon.

go into more details soon. While you’re reading this, take everything in, some While you’re reading this, take everything in, some of it may be out of uof it may be out of understandingnderstanding at the moment, but the goal

at the moment, but the goal of this article is to be used for training first, referencing second.of this article is to be used for training first, referencing second.

Setting up My Robot Setting up My Robot

The easiest mistake an operator can mak

The easiest mistake an operator can make is poorly setting up his robot. e is poorly setting up his robot. A clean setup, with enoughA clean setup, with enough room to work, everything to reach can at times be a task, properly written program, good component parts, and room to work, everything to reach can at times be a task, properly written program, good component parts, and the traveler at his station. Some of these are

the traveler at his station. Some of these are easier to control then others, Obviously as an easier to control then others, Obviously as an operator, your notoperator, your not actually writing the program, however you can

actually writing the program, however you can still inform your superiors of any concerns you have still inform your superiors of any concerns you have with thewith the program, and they will be happy to help get it fix. Experience, Knowledge, and Communication are the three program, and they will be happy to help get it fix. Experience, Knowledge, and Communication are the three key factors to ensuring your area is able

key factors to ensuring your area is able to run at max efficiency.to run at max efficiency.

Proper Program Allotted Proper Program Allotted

Let’s delve deeper into what it takes to

Let’s delve deeper into what it takes to make sure you are in a make sure you are in a situatiosituation to do your best, the last thing an to do your best, the last thing a group leader wants to do, is p

group leader wants to do, is put any operator in a position to ut any operator in a position to fail. We are here to do everfail. We are here to do everything we can to ensureything we can to ensure you have the proper training, tools, and help you need to perform your job. The first thing any operator should you have the proper training, tools, and help you need to perform your job. The first thing any operator should check for is to ensure the correct program is

check for is to ensure the correct program is allotted into the robot. “Allotted” is a term we uallotted into the robot. “Allotted” is a term we u se to say “When Ise to say “When I push the start button, I want to run this program.” Each robot is diff

push the start button, I want to run this program.” Each robot is different in this task; your group leader willerent in this task; your group leader will provide instruction on how to check this.

provide instruction on how to check this. It should be mentioned that a majority of the time, It should be mentioned that a majority of the time, the group leaderthe group leader will have already done this for you.

will have already done this for you.

Proper Staging Proper Staging

Staging your area is the best wa

Staging your area is the best way to set yourself up for success. There are thy to set yourself up for success. There are three golden rules to followree golden rules to follow when staging your area.

when staging your area. 1)

1) The fewer amount of steps you take, The fewer amount of steps you take, the faster you will be. the faster you will be. 5 steps is always faster then 105 steps is always faster then 10 2)

2) Assembly lines work for all aspects; all your components should be Assembly lines work for all aspects; all your components should be in one place, then in one place, then your work table,your work table, followed by your finished part skid. This prevent

followed by your finished part skid. This prevent confusion and lost time trying to remember yourconfusion and lost time trying to remember your steps/sequence

steps/sequence 3)

3) Make sure you have enough room to work comfortably, if you cram everything together, your not goingMake sure you have enough room to work comfortably, if you cram everything together, your not going to make any progress tripping over everything. Find the happy medium of not walking too far, but

to make any progress tripping over everything. Find the happy medium of not walking too far, but having room to perform your job. Each

having room to perform your job. Each person will be different.person will be different.

Proper Tools Proper Tools

Don’t bring a knife to a g

Don’t bring a knife to a gun fight. The same applies to working in un fight. The same applies to working in a factory. You wouldn’t use a screwa factory. You wouldn’t use a screw driver to hammer in a nail. Wh

driver to hammer in a nail. Why use a small angle grinder when any use a small angle grinder when an electric grinder is readily available. Don’t beelectric grinder is readily available. Don’t be afraid to ask for the tools you need

afraid to ask for the tools you need to perform your job. Air grinder, electric grinders, hammers, chisels, stamps,to perform your job. Air grinder, electric grinders, hammers, chisels, stamps, air ratchets, crowbars, etc… If you think there is a tool

air ratchets, crowbars, etc… If you think there is a tool that will help you in performingthat will help you in performingyour task, discuss thisyour task, discuss this with your group leader. Tools that can be justified and are within reason are always a welcomed addition to our with your group leader. Tools that can be justified and are within reason are always a welcomed addition to our repertoire.

(3)

Running My Robot Running My Robot

Your station is setup, your program is allotted, and you have all the tools you need to do the job in front Your station is setup, your program is allotted, and you have all the tools you need to do the job in front of you. By this point, your group

of you. By this point, your group leader has trained you in the leader has trained you in the part your running. We will not discuss the part your running. We will not discuss the act of act of training you personally on a part, as that

training you personally on a part, as that roll is different from job to job. However we will discuss theroll is different from job to job. However we will discuss the similarities they do share.

similarities they do share.

Loading Parts Loading Parts

Each job is different, but the act of properly loading a part can be explained in common steps. Robots Each job is different, but the act of properly loading a part can be explained in common steps. Robots will not know if you do n

will not know if you do not load the part correctly. Loading a ot load the part correctly. Loading a part poorly, forgetting a clamp, or not part poorly, forgetting a clamp, or not cleaningcleaning your cone can cause permanent damage to the robot. To put a price tag on the severity of damaging a torch, a your cone can cause permanent damage to the robot. To put a price tag on the severity of damaging a torch, a rough estimate would set the company back $1,000.00. We do understand that accidents can and do happen, rough estimate would set the company back $1,000.00. We do understand that accidents can and do happen, however, through proper training and coaching,

however, through proper training and coaching, we are minimizing this issue.we are minimizing this issue. Please be consistent in loading your parts, Not all

Please be consistent in loading your parts, Not all jobs require parts to be loaded in a jobs require parts to be loaded in a specific sequence,specific sequence, but finding one and sticking to it will a

but finding one and sticking to it will allow you to become faster. Knowing that llow you to become faster. Knowing that by putting a certain piece inby putting a certain piece in first may make the rest of the parts fit in easier and

first may make the rest of the parts fit in easier and faster. Always be sure that all parts are in their properfaster. Always be sure that all parts are in their proper locations and are secured down

locations and are secured down with either a clamp, spring stop, or bolt. Make with either a clamp, spring stop, or bolt. Make sure if a fixture has multiplesure if a fixture has multiple stages or other parts that run on it, that

stages or other parts that run on it, that all clamps are closed regardless of being loaded all clamps are closed regardless of being loaded or not. All programs areor not. All programs are written with all clamps closed.

written with all clamps closed.

Buttons Galore Buttons Galore

As and operator, were only goin

As and operator, were only going to discuss the main buttons you’ll need to g to discuss the main buttons you’ll need to begin and maintainbegin and maintain production. At first, you may require help

production. At first, you may require help getting the robot to recover from error like “Shock”, getting the robot to recover from error like “Shock”, “Arc“Arc--Fail”, andFail”, and “Out of Arc”, but eventually you’ll be

“Out of Arc”, but eventually you’ll be able to correct this yourself. Each robot able to correct this yourself. Each robot has a box of button has a box of button mounted tomounted to it, or near it on a stand that is considered an “Operators Box.” There are only 4 Buttons you’ll need to concern it, or near it on a stand that is considered an “Operators Box.” There are only 4 Buttons you’ll need to concern yourself with; “Start”, “Auto”, “Servo On”, and “Emergency Stop”. Start and Emergency Stop (E

yourself with; “Start”, “Auto”, “Servo On”, and “Emergency Stop”. Start and Emergency Stop (E-Stop) is self -Stop) is self explanatory. Start will start or resume production on your robot,

explanatory. Start will start or resume production on your robot, Stop will immediately stop the robot regardlessStop will immediately stop the robot regardless of what it is doing.

of what it is doing. Auto will be used to put Auto will be used to put the robot into “Auto” mode. This the robot into “Auto” mode. This must be done any time the must be done any time the robot isrobot is put into “Teach Mode.” This will occur anytime something needs to be adjusted or you are recovering from an put into “Teach Mode.” This will occur anytime something needs to be adjusted or you are recovering from an error. Servo is used to turn the safety curtains back on and this will need to be done anytime you need to push error. Servo is used to turn the safety curtains back on and this will need to be done anytime you need to push the Auto button, or if the safety curtains are b

the Auto button, or if the safety curtains are broken accidently. Often times when a roken accidently. Often times when a group leader will correctgroup leader will correct something using “Teach Mode” the

something using “Teach Mode” they will tell you, “It’s ready,y will tell you, “It’s ready,Just Auto-Servo-Start”, this is the buttonJust Auto-Servo-Start”, this is the button sequence to return to running production.

sequence to return to running production. As you become more familiar with the robot, As you become more familiar with the robot, other buttons will beother buttons will be explained to you.

explained to you.

Fixture and Part Quality Fixture and Part Quality

A quality part is the goal at

A quality part is the goal at all times. This can be hard all times. This can be hard to accomplish if your not working with quato accomplish if your not working with qualitylity tools, or a quality fixture. Documentation will be p

tools, or a quality fixture. Documentation will be p rovided to explain the necessities related to creating qualitrovided to explain the necessities related to creating qualit yy parts. Maintaining the fixture is also the res

parts. Maintaining the fixture is also the responsibility of any and all employee’s in the depponsibility of any and all employee’s in the department. A cleanartment. A clean fixture that is free of BB’s, dirt, debris, or other defects will hinder your ability to produ

fixture that is free of BB’s, dirt, debris, or other defects will hinder your ability to produ ce a perfect part. Don’tce a perfect part. Don’t be afraid to take some time to

be afraid to take some time to scrape or blow off your fixture. A keen scrape or blow off your fixture. A keen eye for this will increase your productioneye for this will increase your production by lowering the chances of having

by lowering the chances of having to fix or rework a part. Fixtures are often to fix or rework a part. Fixtures are often removed between jobs and taken removed between jobs and taken toto a wash booth and thoroughl

a wash booth and thoroughly cleaned with acid and y cleaned with acid and other chemicals. As an operator it is your responsibility toother chemicals. As an operator it is your responsibility to notify a group leader of any problems you notice with a fixture.

notify a group leader of any problems you notice with a fixture.

Error Recovery Documentation Error Recovery Documentation

Documentation can be provided by your group leaders that will walk you through the process of Documentation can be provided by your group leaders that will walk you through the process of correcting a robot after it has one of

correcting a robot after it has one of the three before mentioned ethe three before mentioned errors (Shock, Arc-Fail, Out-of-Arc) as well asrrors (Shock, Arc-Fail, Out-of-Arc) as well as E-Stops and properly allotting programs.

(4)

PART 2 (OTC)

Intro to Programming Intro to Programming

Every programmer starts off as an operator; having a thorou

Every programmer starts off as an operator; having a thorough grasp of running the robot is essential togh grasp of running the robot is essential to understanding how to program the robot. Every Operator has had those moments when they think to

understanding how to program the robot. Every Operator has had those moments when they think to themselves, “Why is the robot doing this, this wa

themselves, “Why is the robot doing this, this wa y? If I were programming this part, I would have doy? If I were programming this part, I would have do ne it likene it like this.” For whatever reason, the programmer made the

this.” For whatever reason, the programmer made the decision to program these parts this way. With thedecision to program these parts this way. With the

following knowledge and information, you will understand why, or maybe, you found a new way to run a part, following knowledge and information, you will understand why, or maybe, you found a new way to run a part, that is A) Faster, B) Of Better Quality, C) More Practical, or all of

that is A) Faster, B) Of Better Quality, C) More Practical, or all of the above.the above. Robotic programming is easily mistaken as one of the

Robotic programming is easily mistaken as one of the more complicated aspects of weld pmore complicated aspects of weld production.roduction. That’s not to say it can’t be intimidating at times. The

That’s not to say it can’t be intimidating at times. The first thing you need to understand aboufirst thing you need to understand about a robot is that itt a robot is that it is just a computer built to do a “P

is just a computer built to do a “Prere--Programmed” task accurately and repetitively. As a pProgrammed” task accurately and repetitively. As a programmer, you willrogrammer, you will learn

learn how to “Teach” these how to “Teach” these robots the steps and actions it will need robots the steps and actions it will need to perform, in the sequence it will need to perform, in the sequence it will need toto perform them. The best way to think of Robotic programming is three dimensional “Connect the dots”. Below perform them. The best way to think of Robotic programming is three dimensional “Connect the dots”. Below

is a snippet of code from one of our programs. is a snippet of code from one of our programs.

001 001 – – HPHP 002 002 – – HPHP 003 003 – – P P 100%100% 004 004 – – P P 100%100% 005

005 – – AS (24V, 200A, 14IPM)AS (24V, 200A, 14IPM) 006

006 – – L L 100i100i 007

007 – – AE (23.5V, 180A, 0.1, 0.0)AE (23.5V, 180A, 0.1, 0.0) 008

008 – – P P 100%100%

At first this code may seem like a foreign langu

At first this code may seem like a foreign language, or at the very least confuage, or at the very least confusing. What your actuallysing. What your actually seeing is th

seeing is the “Robotic Code” a e “Robotic Code” a previous Programmer has put into the robot previous Programmer has put into the robot to perform a task.to perform a task.All the letters andAll the letters and random numbers make very little sense at the mo

random numbers make very little sense at the moment. This demonstration is strictly to show you the structurement. This demonstration is strictly to show you the structure of the code. We will go into

of the code. We will go into further detail of each function later on. further detail of each function later on. ItIt’’s more important to understand thes more important to understand the structure and sequence, then the

structure and sequence, then the commands. The simplest way to think of commands. The simplest way to think of this is in English terms. The Englishthis is in English terms. The English interpretation of any Computer Code

interpretation of any Computer Code is called “is called “Pseudo-Pseudo-Code”Code”. The same code written in English or Pseudo-. The same code written in English or Pseudo-Code would look like this.

Code would look like this. 001

001 – – This is my Home Point, or where This is my Home Point, or where I want the Robot to start from (Safe Position)I want the Robot to start from (Safe Position) 002

002 – – This is where I want to turn mThis is where I want to turn my table into the proper position for my weldy table into the proper position for my weld 003

003 – – The robot needs to move The robot needs to move here first at 100% of its operational speedhere first at 100% of its operational speed 004

004 – – The robot then moves here The robot then moves here at 100% speed to begin its weldat 100% speed to begin its weld 005

005 – – The Robot will start welding at the previouslThe Robot will start welding at the previously stated point, with these settingsy stated point, with these settings 006

006 – – The robot will continue welding to this point, The robot will continue welding to this point, maintaining these settingsmaintaining these settings 007

007 – – The robot will then finish its weld, with these settingsThe robot will then finish its weld, with these settings 008

008 – – The robot will then move to The robot will then move to this point, to clear the part, at 100% this point, to clear the part, at 100% speedspeed This is a lot less intimidating when you see it this way, and is far eas

This is a lot less intimidating when you see it this way, and is far easier to understand. ier to understand. What this articleWhat this article will do, is train you on how

will do, is train you on how to think and relate the robotic codto think and relate the robotic code, to our natural way of thinkine, to our natural way of thinking. You will learng. You will learn how to take a set of instructions we un

(5)

Programmable Points Programmable Points

Progra

Programmable points, such as “P”, “L”, “C”, and “HP” are known as Position Points, for lack of a better mmable points, such as “P”, “L”, “C”, and “HP” are known as Position Points, for lack of a better term. These points can be programmed with a

term. These points can be programmed with a physical position. Meaning, the robot will have to physical position. Meaning, the robot will have to move to thismove to this point to execute any of commands following the poi

point to execute any of commands following the point. These are your “Dots” so to speak in “Connect the dots”nt. These are your “Dots” so to speak in “Connect the dots”.. Each of these points will store information on where the

Each of these points will store information on where the robot moves to. They however robot moves to. They however will each move thewill each move the robot there in a separate manor. Understanding th

robot there in a separate manor. Understanding that manor and utilizing it properly is what at manor and utilizing it properly is what defines adefines a Programmer.

Programmer.

“P” Points “P” Points

Your “P” point is the bread

Your “P” point is the bread and butter of all programs; it will easily make up and butter of all programs; it will easily make up 80% of your program. This80% of your program. This point comes with a speed modifier, which you’ve seen earlier. The modifier is in a percentage based form, and point comes with a speed modifier, which you’ve seen earlier. The modifier is in a percentage based form, and

direc

directly affects the speed of the robot. “Ptly affects the speed of the robot. “P” points when used will cause the ” points when used will cause the robot to move in a slight hoprobot to move in a slight hoppingping manor. It will take the shortest possible path to this point,

manor. It will take the shortest possible path to this point, rotating all axes at the same time, regardless of whatrotating all axes at the same time, regardless of what is in the way. For this reason, “

is in the way. For this reason, “P’s” should never be used in the P’s” should never be used in the middle of a weld.middle of a weld.

“L” Points “L” Points

Your “L” points are, as the n

Your “L” points are, as the name suggests, Linear Points. These will make up ame suggests, Linear Points. These will make up a majority of your welds.a majority of your welds. These points are used mainly for welding, since th

These points are used mainly for welding, since they move the robot in a ey move the robot in a straight line, and will adjust the straight line, and will adjust the axesaxes in the appropriate way to make

in the appropriate way to make sure that happens. “L’s” can also be sure that happens. “L’s” can also be used to get into harder to reach used to get into harder to reach locations,locations, As the linear motion will allow you to sneak

As the linear motion will allow you to sneak past things that would normally cause problems when past things that would normally cause problems when using a “P”.using a “P”. The moveme

The movement modifier associated with “L’s” is different from “P’s” in that it is an nt modifier associated with “L’s” is different from “P’s” in that it is an actual measurable speed.actual measurable speed. You’ll notice when you program an

You’ll notice when you program an “L” point, it defaults to 100i. The “L” point, it defaults to 100i. The “i” is short for Inches“i” is short for Inchesper Minute, whichper Minute, which is exactly as it sounds. 100 inches will be

is exactly as it sounds. 100 inches will be moved in a linear path, in moved in a linear path, in one minute. The onlone minute. The only time this numbery time this number holds no value is during a weld, at which time the movement speed entered for the weld will override any holds no value is during a weld, at which time the movement speed entered for the weld will override any values entered.

values entered.

“C” Points “C” Points

The “C” point is used for circular welds, an

The “C” point is used for circular welds, and can be a d can be a litlittle tricky to master. The most important thing totle tricky to master. The most important thing to remember about programming with these points is they must be used

remember about programming with these points is they must be used in no fewer then three conin no fewer then three consecutive points.secutive points. The robot requires three points because it will use

The robot requires three points because it will use the information gathered to calculate the pthe information gathered to calculate the proper radius of theroper radius of the circle. Using less then three points can cause jump

circle. Using less then three points can cause jumps in speeds, bunny hopping in s in speeds, bunny hopping in the torch, or errors within yourthe torch, or errors within your program. “C’s” carry the same “i” modifier with them that “L’s

program. “C’s” carry the same “i” modifier with them that “L’s” do, and the rules are the same.” do, and the rules are the same.

“HP” Points “HP” Points

The final posi

The final position holding point we’ll discuss is “HP” points. tion holding point we’ll discuss is “HP” points. These points wThese points will be used to determineill be used to determine start and end points of your prog

start and end points of your program, as well as table turns. “HP” or ram, as well as table turns. “HP” or Home Points are the only knowHome Points are the only known pointsn points that will record both the robot’s position, as well as your

that will record both the robot’s position, as well as your table’s position. Trying to rotate and record the table’s position. Trying to rotate and record the tabletable with any other point is futile and will onl

with any other point is futile and will only result in the robot crashing. It is important to remember that “HP’s”y result in the robot crashing. It is important to remember that “HP’s” will always be used in pairs when turning the

will always be used in pairs when turning the table. One point will be used table. One point will be used at the taat the ta ble’s current location, ble’s current location, another at its destination. This will allow the program to be blocked through forward, as well as backward. another at its destination. This will allow the program to be blocked through forward, as well as backward.

“T” Points “T” Points

The next point we will d

The next point we will discuss has multiple purposes, and in my opinion is the iscuss has multiple purposes, and in my opinion is the most versatile point at amost versatile point at a program

programmer’s disposal, the “T’ Point. This point is a Time point, and it holds no actual physical value, meaningmer’s disposal, the “T’ Point. This point is a Time point, and it holds no actual physical value, meaning the robot will make no movements when

the robot will make no movements when it encounters this point. This could be used it encounters this point. This could be used as a “Wait” command. Aas a “Wait” command. A programmer would be able to use

programmer would be able to use this point for Tacking parts during a program, holding this point for Tacking parts during a program, holding the robot in a certainthe robot in a certain position to perform certain tasks like cleaning the cone,

position to perform certain tasks like cleaning the cone, letting the cone soak in letting the cone soak in a solution/gel, letting the conea solution/gel, letting the cone drip dry for a moment to prevent po

drip dry for a moment to prevent porosity, filling in plug welds, or building up rosity, filling in plug welds, or building up a puddle before you ba puddle before you beginegin welding.

(6)

Welding Commands Welding Commands

What we’ve previously covered

What we’ve previously coveredin essence, is 80% of what it in essence, is 80% of what it takes to become a solid takes to become a solid robot programmer.robot programmer. Being able to put your robot where you need, how you need it to be there, is a majority of creating a good

Being able to put your robot where you need, how you need it to be there, is a majority of creating a good program. We will now learn how to make

program. We will now learn how to make the robot weld, where and the robot weld, where and how we want to. Just like how we want to. Just like hand welding,hand welding, tthere is an array of variables that go into here is an array of variables that go into getting the “Perfect” weld. Volts, Amps or wire feed speegetting the “Perfect” weld. Volts, Amps or wire feed spee d, Torchd, Torch angle, Torch movement speed, material thickness,

angle, Torch movement speed, material thickness, Part position, fixture limitation, robot limitations. All of thesePart position, fixture limitation, robot limitations. All of these will have to be answered to

will have to be answered to in order to create a program.in order to create a program.

Arc Start (AS) Arc Start (AS)

The Arc Start or “AS” command

The Arc Start or “AS” command, is used with your programmed points to , is used with your programmed points to tell your robot when and tell your robot when and howhow to weld. This Command will be accompan

to weld. This Command will be accompanied with weld parameters. Just like when hand ied with weld parameters. Just like when hand welding, we need towelding, we need to set these parameters for the situation we are in.

set these parameters for the situation we are in. Finding a combination of parameters that will work Finding a combination of parameters that will work consistentlyconsistently is the key to creating a

is the key to creating a greatgreat program. Good parameters come with experience; don’t be afraid to ask your program. Good parameters come with experience; don’t be afraid to ask your betters what their opinion is.

betters what their opinion is.

The first parameter you’ll be inputting is the Voltage. This is a

The first parameter you’ll be inputting is the Voltage. This is a numerical reference to how “HOT” numerical reference to how “HOT” your your weld will be. The thicker your material, the higher this number will be. This number can very depending on weld will be. The thicker your material, the higher this number will be. This number can very depending on your position in relation to the weld, How

your position in relation to the weld, How large the weld needs to blarge the weld needs to be, as well as how fast the robot e, as well as how fast the robot will bewill be moving while its welding.

moving while its welding.

The second parameter you’ll see is

The second parameter you’ll see is your Amps, or Wire Feeyour Amps, or Wire Feed Speed. Depending on what size wire youd Speed. Depending on what size wire you are running on the robot, this number will have different meanings. Robots running .035” wire will have a 1 are running on the robot, this number will have different meanings. Robots running .035” wire will have a 1--Amp to 2IPM ratio;

Amp to 2IPM ratio; .045” wire will have a 1.045” wire will have a 1-Amp to 1-IPM ratio. This means if you were h-Amp to 1-IPM ratio. This means if you were hand welding thisand welding this part, and the parameters you decided to use had your wire speed set to 200IPM (Inches per Minute) you would part, and the parameters you decided to use had your wire speed set to 200IPM (Inches per Minute) you would be using 200Amps for .035” or 100Amps for .045”.

be using 200Amps for .035” or 100Amps for .045”.You will have to learn both of these ratios, because ourYou will have to learn both of these ratios, because our robots run both sizes of wire

robots run both sizes of wire

The final parameter you will have

The final parameter you will have to provide is the movement speed oto provide is the movement speed of the torch. This speed is recordedf the torch. This speed is recorded in inches per minute. Average speeds consist of 12

in inches per minute. Average speeds consist of 12 – – 24ipm, but there will be times when this will not 24ipm, but there will be times when this will not be thebe the case. Ideally we do our best to make the robot go as fast as we safely can, while producing a quality part. This case. Ideally we do our best to make the robot go as fast as we safely can, while producing a quality part. This may not happen the first time a

may not happen the first time a program is written, although you should always strive for this to be program is written, although you should always strive for this to be the case.the case. This is another “learn from experience” parameter. This parameter can change based on y

This is another “learn from experience” parameter. This parameter can change based on your first two choices.our first two choices.

Arc End (AE) Arc End (AE)

Naturally, what follows an Arc Start, but an Arc End. You’ll see two famili

Naturally, what follows an Arc Start, but an Arc End. You’ll see two familiar parameters here that arear parameters here that are consistent with the Arc Start; Volts and Amperage (Wire Feed Speed).

consistent with the Arc Start; Volts and Amperage (Wire Feed Speed). However you will notice the absence However you will notice the absence of of your mov

your movement speed, and in ement speed, and in its place we have two decimal parameters. Enits place we have two decimal parameters. Enter “Crater Time” and “Post Flow”ter “Crater Time” and “Post Flow”.. Crater time, for all intensive purposes, is a built in “T” P

Crater time, for all intensive purposes, is a built in “T” P oint. By definition, the crater time is the amooint. By definition, the crater time is the amountunt of time the robot will pause at the end

of time the robot will pause at the end of aof a weld, but continue welding at the provided parameters. You’ll noticeweld, but continue welding at the provided parameters. You’ll notice with robots that the end of our welds, the

with robots that the end of our welds, they tend to be smaller then the y tend to be smaller then the original weld size. Crater time is here tooriginal weld size. Crater time is here to correct that. Often crater time is set to 0.2 seconds,

correct that. Often crater time is set to 0.2 seconds, but it can stretch from 0.0 but it can stretch from 0.0 to a full second, depending to a full second, depending on theon the requirements.

requirements.

Post Flow is a term you will recognize from some

Post Flow is a term you will recognize from some of the more modern MIG welders we havof the more modern MIG welders we have around thee around the shop and its functionality is the same. Post Flow is

shop and its functionality is the same. Post Flow is the amount of time, in seconds, the the amount of time, in seconds, the robot will remain at therobot will remain at the end of weld releasing shielding gas to continue

(7)

Weave Start (WS) Weave Start (WS)

Weaving is by far, one of the

Weaving is by far, one of the most useful functions of a robot, when it comes to most useful functions of a robot, when it comes to welding. There is a lotwelding. There is a lot the can be controlled or

the can be controlled or adjusted when it comes to inserting a weave adjusted when it comes to inserting a weave into your weld. Weaving is usually done into your weld. Weaving is usually done atat all times, but there are occasions when this is not

all times, but there are occasions when this is not so. Usually these occasions come from limitations due to theso. Usually these occasions come from limitations due to the robot or the fixture itself. As a programmer, weaving will ad

robot or the fixture itself. As a programmer, weaving will ad size, consistency, and leave size, consistency, and leave you room for error inyou room for error in your parameters. This command will come with setting familiar to those who

your parameters. This command will come with setting familiar to those who understand Geometry or Calculus,understand Geometry or Calculus, Amplitude, Frequency, Stops (¼, Center, ¾).

Amplitude, Frequency, Stops (¼, Center, ¾). The best way to describe weavin

The best way to describe weaving is with a demonstration. As you can g is with a demonstration. As you can see below, all the variables aresee below, all the variables are shown with the exception of the

shown with the exception of the stops.stops.

Amplitude

Amplitude – – _{The amplitude is an inch measurement of the distance the cone is going to weave from the}_{The amplitude is an inch measurement of the distance the cone is going to weave from the}

center of the programmed weld. You

center of the programmed weld. You will have two points to enter in will have two points to enter in here, one for each side. here, one for each side. It is possible toIt is possible to weave ½ inch to the right, an

weave ½ inch to the right, and no weave to the d no weave to the left. This is extremely unorthodox and not left. This is extremely unorthodox and not advised, but it is anadvised, but it is an example

example

Frequency

Frequency – – _{The frequency is the distance}_{The frequency is the distance between “wave}_{between “wavess””. A higher frequency will result in the robot}_{. A higher frequency will result in the robot}

weaving more times in a given distance.

weaving more times in a given distance. Often times we do not have Often times we do not have to adjust the frequency, but there are timesto adjust the frequency, but there are times it will change from 3Hz-6Hz, default is 5Hz

it will change from 3Hz-6Hz, default is 5Hz Stops are not often used, but

Stops are not often used, but are worth mentioning. If you were to care worth mentioning. If you were to cut your weave into quarters, they ut your weave into quarters, they makemake perfect sense. You can allow the robot

perfect sense. You can allow the robot to pause at these locations for a to pause at these locations for a certain number of seconds. This wouldcertain number of seconds. This would allow you to put more weld onto one side of your weave then the other.

allow you to put more weld onto one side of your weave then the other.

WE WE

A Weave End command

A Weave End command is simply telling the robot to stop weaving. Usually this is just placed at is simply telling the robot to stop weaving. Usually this is just placed at the endthe end of the program. If a weave needs

of the program. If a weave needs to be changed for to be changed for a certain weld, you can a certain weld, you can simply insert another WS commandsimply insert another WS command and adjust your settings.