8.6.2.1.3. Setting the Relationship Diagram Between Welding Current/Voltage and Analog Output
When the collaborative robot welding control type is selected as “Controller IO”, the welding current and voltage values are controlled by the magnitude of the control box analog output (control box analog output voltage range is 0 ~ 10V). At this time, it is necessary to configure the linear correspondence between the control box analog output value and the actual welding current and welding voltage values.
As shown in Figure 12, find the “Analog Current Voltage Relationship Diagram” on the welding machine configuration page. “A-V” represents the correspondence between welding current and the control box output analog voltage, and “V-V” represents the correspondence between welding voltage and the control box output analog voltage.
Select “A-V”, input the welding current range 0-1000A, analog output voltage 0-10V, output AO as “Ctrl-AO0” (the analog output port for welding current control is AO0), click the “Configure” button; Under these parameters, when the control box outputs an analog voltage of 1.5V, it corresponds to a welding current of 150A.
Figure 8.6-12 Welding Current vs Output Analog Correspondence Configuration
As shown in Figure 13, click “V-V” to set the correspondence between welding voltage and the control box analog output voltage. Input the welding voltage range as 0-60V, the analog output voltage value as 0-10V, and the output AO as “Ctrl-AO1” (the analog output port for welding voltage control is AO1), then click the “Configure” button. In this case, if the control box AO1 analog output is 3.5V, it actually controls the welding voltage to be 21V.
Figure 8.6-13 Welding Voltage vs Output Analog Correspondence Configuration
8.6.2.1.4. Welding Machine Debugging
As shown in Figure 14, find “Welding Machine Debugging” on the welding machine configuration page. Select process number 1, input the timeout time as 1000ms, click “Gas On”, and the robot will control the welding machine to start supplying shielding gas. Click the “Gas Off” button, and the robot will control the welding machine to stop supplying shielding gas. The operation methods for other buttons like “Arc Start”, “Forward Wire Feed”, “Reverse Wire Feed”, etc., are the same and will not be repeated.
Figure 8.6-14 Welding Machine Debugging
8.6.2.2. “Digital Communication Protocol (UDP)” Welding Control Configuration
When the robot uses the “Digital Communication Protocol” for welding control, it essentially communicates with a PLC via UDP. The robot transmits control data such as arc initiation, wire feeding, gas supply, current, and voltage to the PLC via UDP communication. The PLC then further controls the welding machine via CANOpen bus (or other methods). Simultaneously, the PLC collects actual welding current, voltage, and arc success signals and feeds them back to the robot. (Refer to Appendix 1 for the robot UDP communication protocol content).
In the “Initial” -> “Peripherals” menu bar, click “Welding Machine” to enter the welding machine configuration interface. As shown below:
Figure 8.6-15 Digital Communication Protocol (UDP)
Since the robot communicates with the PLC via UDP, UDP communication parameters need to be configured. The meanings of these parameters are as follows:
IP Address: The IP address of the PLC end for UDP communication. Port Number: The UDP communication port number on the PLC end. Communication Cycle: The cycle for UDP communication between the robot and the PLC, default is 2ms. Packet Loss Detection Cycle, Packet Loss Count: When the number of lost packets within the packet loss detection cycle exceeds the set value, the robot reports a “UDP communication packet loss exception” error and automatically cuts off the communication. Communication Interruption Confirmation Duration: If the robot does not receive a complete frame of PLC feedback data within this duration, it reports a “UDP communication interruption” error alarm and cuts off the UDP communication. Auto-reconnect after Power Restart: Whether the robot automatically attempts to reconnect and recover after detecting a robot power restart. Auto-reconnect after Communication Interruption: Whether the robot automatically attempts to reconnect and recover after detecting a UDP communication interruption. Reconnection Cycle, Reconnection Count: When auto-reconnect after UDP communication interruption is enabled and a interruption is detected, the robot attempts reconnection at the set cycle. If the reconnection count reaches the maximum set value and the connection is still not successful, the robot reports a “UDP communication interruption” error alarm and cuts off the UDP communication.
After configuring the above parameters, click the “Configure” button. After successful configuration, click the “Load” button.
Figure 8.6-16 UDP Communication Configuration
Note
Name: Edit Button
Function: Open/Close UDP communication parameter configuration
Note
Name: Load Button
Function: Load UDP communication
8.6.2.2.1. Welding IO Signal Configuration
Select the DI input ports for the welder status signals and the DO output ports for the welder control signals, then click the “Configure” button. The meanings of each signal are as follows:
Figure 8.6-17 Set Welding Machine Signal Ports
Welder Ready: This signal is output from the welding machine to the robot when the welding machine is ready to perform welding operations.
When the welding machine is not ready due to faults or other reasons, this signal is not input to the robot. At this time, the robot WebApp prompt in the upper right corner “Welder not ready”. If your welding machine does not have a welder ready signal, you can set this port to “-1”.
Figure 8.6-18 Welder Not Ready Error
Figure 8.6-19 Welder Ready Set to “-1”
Arc Success: The arc has been successfully initiated. After the robot outputs the arc initiation signal to the welding machine, it waits for the arc success feedback signal from the welding machine. If the robot does not detect the arc success signal from the welding machine within the set timeout period, the robot reports an “Arc initiation timeout” error.
If the arc success signal is not configured, welding can still be performed using the robot welding function, but the robot will report a “Arc success DI not configured” warning. If your welding machine has an arc success signal output, we recommend configuring this signal for safer welding.
Figure 8.6-20 Arc Initiation Timeout Error
Figure 8.6-21 Arc Success DI Not Configured Warning
Welding Interruption Recovery: Triggered when the arc is unexpectedly interrupted during robot welding or the operator actively pauses welding. When this signal input to the robot changes from invalid to valid after a welding interruption, the robot automatically resumes welding from the original interruption position.
Welding Interruption Exit: Triggered when the arc is unexpectedly interrupted during robot welding or the operator actively pauses welding. When this signal input to the robot changes from invalid to valid after a welding interruption, the robot terminates welding. After termination, welding cannot be resumed.
Welding Arc Initiation: The DO output port through which the robot controls the welding machine to initiate the arc. When the robot program executes the arc initiation command, the corresponding DO output port for arc initiation automatically outputs a valid signal.
Gas Detection: The DO output port through which the robot controls the welding machine to supply gas. When the robot executes the welding gas supply command, the corresponding DO output port for gas supply automatically outputs a valid signal.
Forward Wire Feed: The DO output port through which the robot controls the welding machine for forward wire feeding. When the robot executes the forward wire feed command, the corresponding DO output port for forward wire feed automatically outputs a valid signal.
Reverse Wire Feed: The DO output port through which the robot controls the welding machine for reverse wire feeding. When the robot executes the reverse wire feed command, the corresponding DO output port for reverse wire feed automatically outputs a valid signal.
8.6.2.2.2. Welding Process Parameter Configuration
As shown in Figure 22, find the “Welding Process Parameters” section on the welding configuration page. The collaborative robot provides 100 sets of welding process parameters, numbered 0 to 99. Process number 0 indicates not using the welding process curve, while process numbers 1-99 use the welding process curve.
Figure 8.6-22 Welding Process Parameter Configuration
When using the welding process curve, take selecting welding process number 1 as an example. Input the parameters from Arc Initiation Current to Arc Closing Time as shown in Figure 8, then click the “Configure” button. The actual welding process represented by these parameters is as follows:
① Set welding current 200A, voltage 23V; ② Execute arc initiation, wait for arc success; ③ After arc success, maintain the arc for 500ms (Arc initiation time, robot does not move); ④ Set welding current 150A, welding voltage 21V, then the robot starts moving and performs welding; ⑤ After welding to the end point, set welding current to 100A, welding voltage to 19V (Arc closing current, Arc closing voltage); ⑥ After setting the arc closing current and voltage, maintain arc burning for 500ms (robot does not move), finally extinguish the arc.
When not using the welding process parameters, i.e., selecting welding process parameter number 0, the welding process is: ① Set the corresponding welding current and welding voltage via the set current/voltage interface; ② The robot controls the welding machine to initiate the arc and waits for arc success; ③ After arc success, the robot starts moving and performs welding; ④ The robot extinguishes the arc immediately after welding to the end point.
Figure 8.6-23 Not Using Welding Process Curve
8.6.2.2.3. Welding Machine Debugging
Find “Welding Machine Debugging” on the welding machine configuration page. Select process number 1, input the timeout time as 1000ms, click “Gas On”, and the robot will control the welding machine to start supplying shielding gas. Click the “Gas Off” button, and the robot will control the welding machine to stop supplying shielding gas. The operation methods for other buttons like “Arc Start”, “Forward Wire Feed”, “Reverse Wire Feed”, etc., are the same and will not be repeated.
Figure 8.5-24 Welding Machine Debugging
8.6.3. Welding Program Writing
8.6.3.1. Writing Programs Using Welding Process Curves
When using the welding process curve (i.e., selecting welding process parameter numbers 1 ~ 99), the voltage and current control during the welding process follows the curve parameters set for a specific process number, and there is no need to separately add instructions to set welding voltage and current. As shown in Figure 25, click “Teach” -> “Program Programming”, and create a new user program “testWeld.lua”.
Figure 8.6-25 Create “testWeld.lua” Program
In the opened welding instruction addition page, select the control type as “Controller I/O” (select based on the actual configured welding control method), select the welding process number as 1 (Process number 0 does not use the welding process curve, numbers 1-99 do), set the maximum wait time as 10000ms, click the “Arc Start” button and then the “Arc Close” button sequentially, and finally click “Apply”.
Figure 8.6-26 Welding Instruction Addition
Now the “testWeld.lua” program has added the welding arc start instruction and the welding arc close instruction. Since the arc start and close operations selected welding process curve number 1, the voltage and current control during the welding process follows the curve parameters set for process number 1, and there is no need to separately add instructions to set welding voltage and current.
Figure 8.6-27 Arc Start and Close Program
Add two linear motion instructions and adjust the instruction order so that the robot first moves to point “P1”, executes arc start, then moves to point “P2”, and executes arc close, achieving welding from point “P1” to point “P2”.
Figure 8.6-28 Robot Welding from Point P1 to P2