8.6.6.2.2. Welder Open Protocol Analysis

8.6.6.2.2. Welder Open Protocol Analysis

The welder open protocol mainly consists of three parts:

① Establish Communication Connection: Specify the protocol number id (must match the protocol number set when loading the open protocol), welder IP address, port number, and other parameters. Use the “ModbusTCPMasterCreate()” command to establish a ModbusTCP connection between the robot and the welder.

② Cyclically Write Control Data to Welder: When the welder open protocol executes, it first reads the current welder control data from the robot controller’s internal memory, then writes this data to the welder to control its actions. The return values of the instruction “WeldingGetCtrlState()”, which reads robot welding control data in the protocol, are defined in Table 2-1. The control data can be decomposed according to the actual welder control register definitions and then written to the welder via ModbusTCP.

Table 8.19-1 WeldingGetCtrlState() Return Values

③ Cyclically Read Status Data from Welder: The welder open protocol first reads real-time status data from the welder via ModbusTCP, then writes the relevant data to the robot controller, allowing the robot to monitor the welder’s real-time action status. The parameter for the protocol’s interface “WeldingSetRealtimeState()”, which sets the welder status in the robot, is an array containing all welder statuses (note: in the open protocol LUA, array indexing starts from 1) as shown in Table 2-2. The welder status data read via ModbusTCP according to the actual welder status register definitions can be combined into the welder status array and written to the robot controller.

Table 8.19-2 WeldingSetRealtimeState() Detailed Parameters

8.6.6.2.3. Welding Machine Open Protocol Upload and Load

Successively click “Initial”, “Peripherals”, “Control Box”, “Peripheral Open Protocol”, then click the “Upload” button to upload the welding machine open protocol file “CtrlDev_WELDING.lua” (The protocol file name must start with CtrlDev_ and have the extension .lua).

Figure 8.6‑39 Upload Welding Machine Open Protocol

In “Protocol Configuration”, select a “Protocol Number” (needs to match the protocol number in the open protocol file), here using number 1 as an example, and select the “Protocol Name” as the welding machine open protocol “CtrlDev_WELDING.lua”. Click the “Configure” button. At this point, the configured welding machine open protocol is displayed in “Device Operation and Status”.

Figure 8.6‑40 Configure Welding Machine Open Protocol

Click the “Connect” button to load the welding machine open protocol. The running status indicator lights up, indicating that the robot and the welding machine are communicating.

Figure 8.6‑41 Load Welding Machine Open Protocol

8.6.6.2.4. Welding Machine Debugging

Before debugging the welding machine, please ensure that the welding machine open protocol has been loaded normally and the relevant register address configurations are correct.

Successively click “Initial”, “Peripherals”, “Welding Machine”, and select “Digital Communication Protocol (ModbusTcp)”.

Figure 8.6‑42 Select “Digital Communication Protocol (ModbusTcp)”

Click buttons such as “Arc Start”, “Arc Stop”, “Gas On”, “Gas Off”, etc., and observe whether the actual welding machine actions are consistent with the settings. If the welding machine does not perform the set actions, check if the register configuration in the welding machine open protocol is incorrect and perform further debugging.

Figure 8.6‑43 Welding Machine Debugging

8.6.6.2.5. Welding Program Writing

Click “Initial”, “Teach Program”, “Program Programming”, and create a new program “testWeld.lua”.

Figure 8.6‑44 Create Welding LUA Program

Click the “Welding” button. In the pop-up welding command addition page, select “Digital Communication Protocol (Modbus Tcp)”. Then successively select “Arc Start”, click “Add”, select “Arc Stop”, click “Add”, and finally click the “Apply” button.

Figure 8.6‑45 Add Arc Start and Arc Stop Commands

At this point, the Arc Start and Arc Stop commands have been successfully added to “testWeld.lua”.

Figure 8.6‑46 Added Arc Start and Arc Stop Commands

Successively add the welding start point and welding end point. Switch the robot to automatic mode, and under safe conditions, start the program. The robot will then control the welding machine to perform welding along one weld seam.

Figure 8.6‑47 Welding Program

8.6.6.2.6. Welding Machine Open Protocol Unload

Successively click “Initial”, “Peripherals”, “Control Box”, “Peripheral Open Protocol”. In the “Device Operation and Status” section, click the “Unload” button.

Figure 8.6‑48 Unload Open Protocol

At this point, the protocol running status indicator turns off.

Figure 8.6‑49 Open Protocol Unloaded

If welding debugging is performed or a welding program is executed at this time, the robot will report a “Protocol Not Loaded Error” in the lower left corner of the WebApp.

Figure 8.6‑50 Protocol Not Loaded Error

8.7. Extended Axis Configuration

In “Initial” -> “Peripherals”, click “Extended Axis” to enter the Extended Axis configuration interface, which includes Extended Axis Coordinate System configuration and Extended Axis Peripheral configuration. The interface when first entering Extended Axis configuration is as follows:

Figure 8.7‑1 Initial Extended Axis Configuration Interface

Currently, Extended Axis Peripheral configuration is divided into the following two types based on communication method:

• Controller + PLC (UDP Communication).

• Controller + Servo Drive (485 Communication).

8.7.1. Extended Axis Coordinate System

The Extended Axis Coordinate System settings interface allows for the application, clearing, and configuration of the extended axis coordinate system.

Note

Name: Apply

Function: Apply the extended axis coordinate system

Note

Name: Clear

Function: Clear extended axis coordinate system data

There are 5 numbers in the drop-down list for the Extended Axis Coordinate System, from exaxis0 to exaxis4. Selecting a corresponding coordinate system will display its coordinate values below. After selecting a coordinate system, click the “Apply” button, and the currently used extended axis coordinate system changes to the selected one, as shown below.

Figure 8.7‑2 Extended Axis Coordinate System

Select an extended axis coordinate system other than “exaxis0”, click “Configure” to enter the Extended Axis Coordinate System configuration interface to reset the extended axis coordinate system for that number. As shown below:

Important

• Before calibration, first clear the extended axis coordinate system to be calibrated, and apply this extended axis coordinate system.

• Select the extended axis number. “Get Info” can retrieve the drive information for the corresponding extended axis, which can be used for parameter configuration.

Figure 8.7‑3 Extended Axis Coordinate System Calibration

The current extended axis solutions are as follows:

• 0 - Single Degree of Freedom Linear Slide

• 1 - Two Degree of Freedom L-type Positioner

• 2 - Three Degree of Freedom (Temporarily unavailable)

• 3 - Four Degree of Freedom (Temporarily unavailable)

• 4 - Single Degree of Freedom Positioner

• 5 - Two Degree of Freedom AGV

Single Degree of Freedom Linear Slide: First set the DH parameters, then set the robot’s position relative to the extended axis (the linear slide is considered on the extended axis). If not calibrating, just click Save; at this point, the extended axis can only move asynchronously.

Figure 8.7-4 Linear Slide DH Parameter Configuration

Figure 8.7-5 Linear Slide – Robot Position Relative to Extended Axis Configuration

If synchronous movement with the robot is required, at the extended axis zero point, click the operation area ‘Eaxis’ to enable the extended axis. Align the robot end center point (using the tool end point under the applied tool coordinate system) to a fixed point on the extended axis with two different postures, setting Point 1 and Point 2 respectively.

Figure 8.7‑6 Linear Slide Calibration Points 1 and 2

Disable the axis, move the extended axis a certain distance, enable it again, and similarly align the robot end center point to the previous fixed point, setting Point 3. Disable the axis, move the extended axis back to the zero point, and enable the extended axis. Move the robot end center point to a point in space directly above the fixed point, setting Point 4. Calculate the coordinate system and save.

Figure 8.7‑7 Linear Slide Calibration Points 3 and 4

Two Degree of Freedom L-type Positioner: The positioner consists of two extended axes. First set the DH parameters. Measure the DH parameters of the positioner according to the diagram and input them into the boxes. Set the robot’s position relative to the extended axis (the positioner is considered outside the extended axis). If not calibrating, just click Save; at this point, the extended axes can only move asynchronously.

Figure 8.7‑8 Two DOF L-type Positioner DH Parameter Configuration

Figure 8.7‑9 Two DOF L-type Positioner – Robot Position Relative to Extended Axis

If synchronous movement with the robot is required, at the extended axes zero point, click the operation area ‘Eaxis’ to enable the extended axes. Establish a coordinate system on the positioner. Select a point and input its Cartesian pose in that coordinate system. For example, selecting a point in the positive Y direction, measuring Y as 100mm, input the values as shown in the figure. Click “Reference Point” to set the reference point. The subsequent four calibration points all require aligning the robot end center point (using the tool end point under the applied tool coordinate system) to this reference point.

Figure 8.7‑10 Two DOF L-type Positioner – Reference Point Configuration

Align the robot end center point (using the tool end point under the applied tool coordinate system) to this reference point and set Point 1. Click the operation area ‘Eaxis’ to jog the two axes a small distance, align the robot end center point to the reference point, and set Point 2. Continue jogging the two axes, align the robot end center point to the reference point, and set Point 3. Finally, continue jogging the two axes, align the robot end center point to the reference point, and set Point 4. Click “Calculate” to get the coordinate system result, then click “Save” and “Apply”.

Figure 8.7‑11 Two DOF L-type Positioner Calibration

Single Degree of Freedom Positioner: Consists of one rotating extended axis. Set the DH parameters to 0. Set the robot’s position relative to the extended axis as outside the extended axis. If not calibrating, just click Save; at this point, the extended axis can only move asynchronously.

Figure 8.7‑12 Single DOF Positioner DH Parameter Configuration

Figure 8.7‑13 Single DOF Positioner – Robot Position Relative to Extended Axis

If synchronous movement with the robot is required, at the extended axis zero point, click the operation area ‘Eaxis’ to enable the extended axis. Establish a coordinate system on the positioner. Select a point and input its Cartesian pose in that coordinate system. Click “Reference Point” to set the reference point.

Figure 8.7‑14 Single DOF Positioner Reference Point Configuration

The subsequent four calibration points all require aligning the robot end center point (using the tool end point under the applied tool coordinate system) to this reference point. Align the robot end center point to this reference point and set Point 1. Click the operation area ‘Eaxis’ to jog the rotation axis a small distance, align the robot end center point to the reference point, and set Point 2. Continue jogging the rotation axis, align the robot end center point to the reference point, and set Point 3. Finally, continue jogging the rotation axis, align the robot end center point to the reference point, and set Point 4. Click “Calculate” to get the coordinate system result, then click “Save” and “Apply”.

Figure 8.7‑15 Single DOF Positioner Calibration

Important

1. The extended axis coordinate system is calibrated based on the tool coordinate system and needs to be established on the basis of an already created tool coordinate system.

2. Extended axis systems generally use exaxis1~exaxis4. Applying exaxis0 means no extended axis coordinate system is used. When calibrating an extended axis coordinate system, first apply the extended axis coordinate system to exaxis0, then select another extended axis coordinate system for calibration and application.

8.7.2. Controller + PLC (UDP Communication)

Before using the extended axis UDP communication method, it is necessary to first establish the corresponding extended axis coordinate system, configure the corresponding extended axis solution under that coordinate system, and apply the established tool coordinate system during program teaching. The extended axis function is primarily used in conjunction with the welding machine function and the laser tracking sensor function.

Figure 8.7‑16 Extended Axis Coordinate System Application and Current Extended Axis Solution Display

When only needing to modify the current extended axis coordinate system, select the coordinate system in the Peripheral Extended Axis configuration interface to apply it. When needing to change the extended axis solution, enter the Extended Axis Coordinate System configuration interface to modify it.

When the extended axis solution is “0 - Single Degree of Freedom Linear Slide”, “1 - Two Degree of Freedom L-type Positioner”, “2 - Three Degree of Freedom”, “3 - Four Degree of Freedom”, or “4 - Single Degree of Freedom Positioner”, after successful UDP communication configuration, the interface displays “UDP Extended Axis” and “Positioning Completion Time Setting” content. When the extended axis solution is “5 - Two Degree of Freedom AGV”, the interface displays “Two Degree of Freedom AGV Test” content.

8.7.2.1. UDP Communication Configuration

Note

Name: Edit Button

Function: UDP communication parameter configuration

Note

Name: Load Button

Function: Load UDP communication

Step1: Configure extended axis UDP communication parameters: Set IP Address, Port Number, Communication Cycle, Packet Loss Detection Cycle, Packet Loss Count, etc. The Reconnection Cycle and Reconnection Count can only be configured after the Communication Interruption Auto-reconnect switch is turned on.

• IP Address: Custom IP address;

• Port Number: Define according to the actual situation;

• Communication Cycle: Define according to the actual situation, unit ms;

• Packet Loss Detection Communication Cycle: 10 ~ 1000 ms;

• Packet Loss Count: 1 ~ 100;

• Communication Interruption Confirmation Duration: 0 ~ 500 ms;

• Power-off Restart Auto-reconnect: On/Off;

• Communication Interruption Auto-reconnect: On/Off;

• Reconnection Cycle: 1 ~ 1000 ms;

• Reconnection Count: 1 ~ 100;

Figure 8.7‑17 Extended Axis UDP Communication Parameter Configuration

Important

1. After setting the Communication Disconnect Confirmation Duration, communication disconnect is confirmed and an error is reported only when the communication abnormality exceeds this duration.

2. After UDP communication is disconnected, a UDP disconnect error is triggered (can be reset). Click the Clear Warning Information button, and UDP communication will be re-established.

Step2: After successful communication parameter configuration, click the “Load” button to establish UDP communication. After successful communication, the button in front of “UDP Communication Configuration” turns green. Check the extended axis status in the robot’s various status views; the extended axis should be servoed and in position.

Figure 8.7‑18 Extended Axis UDP Communication Established

Figure 8.7‑19 Extended Axis Servo Ready

Important

1. When UDP communication is not established, UDP extended axis number information cannot be configured or viewed.

2. Before loading extended axis UDP communication, be sure to first configure and apply an extended axis coordinate system other than number 0.

8.7.2.2. UDP Extended Axis

Note

Name: Edit Button

Function: Extended axis parameter configuration

Note

Name: Enable Button

Function: Extended axis enabled state. Clicking the button disables the extended axis.

Note

Name: Disable Button

Function: Extended axis disabled state. Clicking the button enables the extended axis.

Note

Name: Homing Button

Function: Set extended axis homing method

Note

Name: Test Button

Function: Extended axis function test

Step1: Select any extended axis number (currently only numbers 1, 2, 3, 4 are available). Click the “Edit” button behind the extended axis number to enter the detailed configuration interface. Set Axis Type, Axis Direction, Operating Speed, Acceleration, Positive Limit, Negative Limit, Lead, Encoder Resolution, Start Offset, Manufacturer, Model, and Mode. Click “Configure” to complete the configuration.

• Axis Type: Linear Slide, Rotary Axis, Infinite Rotary Axis;

• Axis Direction: Positive / Negative;

• Operating Speed: 0~2000 mm/s;

• Acceleration: 0 ~ 2000 mm/s²;

• Positive Limit: 0 ~ 50000;

• Negative Limit: -50000 ~ 0;

• Lead: 0~1000;

• Encoder Resolution: 0 ~ 10000000;

• Start Offset: 0 ~ 10000 mm;

• Manufacturer: Hechuan, Huichuan, Panasonic;

• Model: Automatically matched model list based on the manufacturer;

• Mode: Incremental System and Absolute Position System;

Figure 8.7‑20 Extended Axis Parameter Configuration

Step2: After completing the extended axis parameter configuration, click the “Disable” button to enable the corresponding extended axis number. After successful enabling, the homing method can be set and the extended axis can be tested. When the extended axis is not enabled, the homing method setting and extended axis test cannot be performed.

Figure 8.7‑21 Extended Axis Enable/Disable

Step3: If the extended axis is not successfully enabled, the button to enter the settings interface is grayed out. After the extended axis is successfully enabled, click the “Homing” button to enter the homing method setting interface. Set the Homing Method, Homing Speed, and Zero Latch Speed. Click the “Set” button, and the extended axis will start homing. The homing status will be displayed in the blank area below the Axis Direction. When the “Homing Completed” prompt appears, it indicates successful extended axis zero point setting.

• Homing Method: Current Position Homing, Negative Limit Homing, Positive Limit Homing;

• Homing Speed: 0~2000 mm/s;

• Zero Latch Speed: 0~2000 mm/s;

Figure 8.7‑22 Homing Method Setting

Step4: If the extended axis is not successfully enabled, the button to enter the settings interface is grayed out. After the extended axis is successfully enabled and the homing method is set, click the “Test” button to enter the extended axis test interface. Set the Running Speed, Acceleration, and Maximum Distance to test the extended axis with forward rotation and reverse rotation. During rotation, you can click the “Stop” button to test if the extended axis can stop normally.

Figure 8.7‑23 Extended Axis Test

Step5: The extended axis is often used in conjunction with a laser sensor. In this case, the laser sensor is usually installed externally. The sensor reference point configuration needs to use the three-point calibration method instead of the previously used six-point calibration method. Align the tool center point to the bottom middle point of the right cross-section (the side closer to the camera) and set Point 1. Align the tool center point to the bottom middle point of the other cross-section (the left cross-section) and set Point 2. Move the tool center point to the top middle point of the right cross-section of the sensor and set Point 3. Calculate and save, then click Apply to complete the three-point calibration.

Figure 8.7‑24 Sensor Three-Point Calibration

Step6: In the “Teach Program” -> “Program Programming” interface, select the “Extended Axis” command from the peripheral instructions. Add instructions in the appropriate places according to the specific program teaching requirements.

Figure 8.7‑25 Extended Axis Command Editing

8.7.2.3. Extended Axes with Laser Tracking Welding Teaching Program

8.7.2.4. Positioning Completion Time

After the extended axis establishes UDP communication, input the time and click the “Configure” button to complete the setting. This configuration item is used to monitor the time when the extended axis motion stops.

Figure 8.7‑26 Positioning Completion Time Configuration

8.7.3. Two-DOF Trolley Test

This content is displayed in the UDP communication interface only when the extended axis scheme is set to “5-Two-DOF Trolley” in the extended axis coordinate system configuration; otherwise, it cannot be viewed.

Figure 8.7‑27 Interface for Extended Axis Scheme “5-Two-DOF Trolley”

Important

The two-DOF trolley by default uses extended axis numbers 1 and 2. After UDP communication is successful, check the servo ready status for extended axes 1 and 2 via the extended axis status in the robot’s various status monitors.

Figure 8.7‑28 Two-DOF Trolley Extended Axis Servo Ready

Note

Name: Enable Button

Function: Extended axis enabled state. Click the button to disable the extended axis.

Note

Name: Disable Button

Function: Extended axis disabled state. Click the button to enable the extended axis.

Note

Name: Homing Button

Function: Home the extended axis at the current position.

Note

Name: Test Button

Function: Test the two-DOF trolley functionality.

Step1: After UDP communication is successful, click the “Disable” button to enable the extended axes corresponding to the two-DOF trolley. Check that extended axes 1 and 2 are servo enabled via the extended axis status in the robot’s various status monitors.

Figure 8.7‑29 Two-DOF Trolley Extended Axes Enabled

Step2: After the extended axes are successfully enabled, click the “Homing” button to set the current position of the extended axes as home. If homing is successful, the test button becomes highlighted; otherwise, it remains grayed out.

Figure 8.7‑30 Two-DOF Trolley Current Position Homing Successful

Step3: After the two-DOF trolley’s current position homing is successful, click the “Test” button to enter the interface. Select the motion mode, input parameters for motion testing, and click the “Stop” button during motion to test the stop function.

• Motion Mode: Linear / Arc;

• Distance: -5000~5000mm (Linear motion mode);

• Radius: 1~5000mm (Linear motion mode);

• Angle: -360~360° (Arc motion mode);

• Speed: 1~100%

Figure 8.7‑31 Two-DOF Trolley Test

8.7.4. Controller + Servo Drive (485 Communication)

8.7.4.1. Hardware Wiring

Before using RS485 communication to control the servo extended axis, please first connect the RS485 communication interface of the servo drive to the RS485 communication interface on the robot control box. The electrical interface diagram for the Faro Robot Yizhizao control box is as follows:

Figure 8.7‑32 Faro Robot Mini Control Box Electrical Interface Diagram

Taking the Dynatek servo drive model FD100-750C as an example, refer to the drive panel terminal diagram and the X3A-IN terminal definition of the FD100-750C. When configuring the robot to communicate with the FD100-750C servo extended axis, it is necessary to connect the 485-A0 terminal and 485-B0 terminal on the control box to pins 4 and 5 of the drive’s X3A-IN terminal, respectively. (Please note: You might see a terminal marked “485” on the servo drive panel. This terminal is currently not available for user use. Do not connect your RS485 communication cable to this terminal). Additionally, if connecting multiple servo drives and this drive is the last in the chain, it is necessary to turn on the RS485 communication termination resistor dip switch (No. 2 dip switch) on the panel.

Figure 8.7‑33 FD100-750C Drive Panel

Figure 8.7‑34 FD100-750C X3A-IN Terminal Definition

8.7.4.2. Communication Configuration

After ensuring your RS485 communication cable is correctly connected and both the robot and servo extended axis are powered on normally, open the robot WebApp.

Click on the image with the combination “Controller + Servo Drive” to enter the detailed configuration interface. In the servo drive configuration, select the number as “1” (Please note: When multiple servos are connected, this number is used to distinguish different servos, we will mention this number multiple times later), the manufacturer as “Dynatek”, select the corresponding servo drive model, here the model is “FD00-750C”, the software version is V1.0, fill in the resolution corresponding to the servo drive, here it is 131072, fill in the mechanical transmission ratio according to your mechanism model, here it is 15.45, and click the “Configure” button.

Figure 8.7‑35 Servo Drive Configuration

So far, we have completed the 485 communication configuration between the robot and the servo drive. You can view the real-time status information of the servo in the “Servo Status Bar” on the right side of the WebApp, as shown below:

Figure 8.7‑36 Servo Status Bar

Now you need to set the enable and homing method for the extended axis device in order, and then you can perform certain motion tests. Please follow this manual for the following test operations under safe conditions.