Transcript Software and Networking Robots

Software and Networking
Robots Now and in the Future
Martin M. Weir / Kevin Pagano
Panasonic Factory Automation
October 22nd 2002
Canadian Welding Association
Canadian Welding Association October 22, 2002
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Software and Networking Robots Now and in the Future
TYPES OF SOFTWARE IN A WELDING ROBOTIC
SYSTEM CONSIST OF THE FOLLOWING…….
WELDING EQUIPMENT SOFTWARE
•WELDING EQUIPMENT TO ROBOT
•ROBOT SOFTWARE TO OPERATOR
•ROBOT NETWORKING COMMUNICATIONS
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Software and Networking Robots Now and in the Future
WELDING EQUIPMENT SOFTWARE
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PAST AND PRESENT TECHNOLOGY
 SET WIRE FEED SPEED (AMPS)
 SET AVERAGE VOLTAGE
 LIMITED ARC CONTROL BY HARDWARE
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PRESENT AND FUTURE TECHNOLOGY
 OPERATOR SETS VOLTAGE AND WIRE FEED SPEED (AMPS)
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THEN THE WELDER SOFTWARE SETS
 PEAK CURRENT
 BASE CURRENT
 PULSE FREQUENCY
 CURRENT RISING/FALL TIMES AND RATES
 SHORT CIRCUITING VARIBLES IN CV MODE
Canadian Welding Association October 22, 2002
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Software and Networking Robots Now and in the Future
WELDING EQUIPMENT SOFTWARE
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ARC COMMUNICATION
 ARTIFICIALLY INTELLIGENT (A.I.) POWER SUPPLIES CAN
COMMUNICATE TO THE ARC WITH REAL TIME FEEDBACK.
 HIGH SPEED TRANSISTORS COMBINED WITH REAL TIME
FEEDBACK INSURES THAT SOFTWARE INSTRUCTIONS ARE
CARRIED OUT.
 A.I. POWER SUPPLIES HAVE AN INTERNAL DATA BASE THAT
PROVIDES THE INTERACTION OF THE WELDING POWER
SOURCE PROCESS VARIBLES.
 A.I. POWER SUPPLIES USE SOFTWARE TO SEPARATE THE
WELDING ARC INTO THREE SPECIFIC AREAS:
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Software and Networking Robots Now and in the Future
THREE SPECIFIC AREAS
Welding
A
Starting
Finishing
M
P
S
TIME
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Software and Networking Robots Now and in the Future
Software Controlled Arc Start
CONVENTIONAL INVERTER
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A.I. INVERTER
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Software and Networking Robots Now and in the Future
STEADY STATE PULSING
90%Ar10%CO2
210 Amps. 320 IPM, 23 Volts
CONVENTIONAL INVERTER
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A.I. INVERTER
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Software and Networking Robots Now and in the Future
STEADY STATE PULSING
90%Ar10%CO2
210 Amps. 320 IPM, 23 Volts (welding over tack)
CONVENTIONAL INVERTER
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A.I. INVERTER
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Software and Networking Robots Now and in the Future
Software Controlled Arc End
CONVENTIONAL INVERTER
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A.I. INVERTER
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Software and Networking Robots Now and in the Future
WELDING EQUIPMENT TO ROBOT
 PAST AND PRESENT TECHNOLOGY
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INTERFACE UNIT REQUIRED BETWEEN ROBOT AND WELDER:
 ANALOG SIGNAL FOR WIRE FEED SPEED / VOLTAGE
LIMITED CONTROL DO TO HARDWARE CONSTRAINTS.
 PRESENT AND FUTURE TECHNOLOGY
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NO WELDER INTERFACE UNIT REQUIRED:
SINGLE SERIAL CABLE CONNECTION
 RS-422 OR DEVICE NET
COMMUNICATION IS NOW 100% SOFTWARE BASE.
TOTAL CONTROL OF POWER SUPPLY CAN BE REALIZED.
 EXAMPLE: WAVESHAPE PER WELD OR GLOBALLY
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Software and Networking Robots Now and in the Future
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FULLY DIGITAL WELDING SYSTEM
 AUTO RECOGNITION OF WELDER
 DIGITAL CALIBRATION
 TOTAL WAVEFORM CONTROL
 CONNECT MULTIPLE WELDERS
 WELDER FRONT PANEL IS INACTIVE OE ELIMINATED
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PREVENTS ACCIDENTAL MOVEMENT OF THE KNOBS AND
THE SWITCHES ON THE FRONT PANEL.
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Software and Networking Robots Now and in the Future
ROBOT SOFTWARE TO THE OPERATOR
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PAST AND PRESENT TECHNOLOGY
 TEACH PENDANTS (PRIMARY USER INTERFACE)
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LIMITED TO ROBOT MANUFACTURES PROGRAMMING
STYLE
NOT SO USER FRIENDLY
NOT FLEXIBLE - “CAN NOT CHANGE”
LACK OF INFORMATION
DEDICATED FUNCTION KEYS
ROBOT REQUIRED FOR TRAINING
Canadian Welding Association October 22, 2002
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Software and Networking Robots Now and in the Future
PRESENT AND FUTURE TECHNOLOGY
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TEACH PENDANTS
 WINDOWS INTERFACE
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“USER FRIENDLINESS”
 LARGER DISPLAY WITH COLOR
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SPLIT SCREEN CAPABILITIES
 FONT SIZE SELECTION
 MORE INFORMATION DISPLAYED ON PENDANT
 INCREASED PROGRAMMING CAPABILITIES
 UNLIMITED FUTURE POSSIBILITIES
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Software and Networking Robots Now and in the Future
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Windows
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CE Operating System
ICON BASED
VISUAL
Color Graphics
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Software and Networking Robots Now and in the Future
Improved “User Friendliness”
Window Functions such As:
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Copy, Cut, Paste
Find
Replace
Save
Save As
Help
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Software and Networking Robots Now and in the Future
Off-line Editing Pendant
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Edit programs from the comfort of your office.
Same TP as that used in production
PC based Robot Simulator
 Connect to your PC with actual teach pendant
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True off-line training system
 Hands on experience without having to
purchase an additional robot
 Develop technicians without stopping
production
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Develop programs off-line
 Debug program logic
 Develop new programs for upcoming jobs
 Add comments to existing programs
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Software and Networking Robots Now and in the Future
Increased Programming Power
 Updated Command Structure
 Updated Math Functions
 Updated Configuration Capabilities
 Updated Connectivity
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Software and Networking Robots Now and in the Future
ROBOT NETWORKING COMMUNICATIONS
 PAST AND PRESENT TECHNOLOGY
MANIPULATOR
CONTROLLER
WELDER
PLC
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LIMIT
SWITCH
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Software and Networking Robots Now and in the Future
ROBOT NETWORKING COMMUNICATIONS
 PRESENT AND FUTURE TECHNOLOGY
ETHERNET
ISDN
Ｐ
PLC
DEVICENET
SENSOR
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Software and Networking Robots Now and in the Future
Through the power of Windows CE
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Access production schedules
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Upload/Download programs from server
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Share files between Robot cells
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Remote servicing via Internet Connection
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Production log book on the Teach Pendant
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Trouble shooting or best practices guide can be developed by your personnel
and stored on the Teach Pendant for future use.
Internet Explorer for Internet / Intranet Connection
Outlook Express- Can E-mail operator specific instructions- “Let me know
when the test parts are finished”
ALL THIS CAN BE DONE DIRECTLY FROM THE TEACHING
PENDANT
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Software and Networking Robots Now and in the Future
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Unlimited Connectivity
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PCMCIA Connection Slots
• Connection to various devices via the open
slot configuration
• Compact Flash Cards, CD-ROM, Floppy
Drive
• Unlimited memory storage capability
• Wireless Networking, Modem
• Web-Cam
• Ethernet
• PS2 Connection Port
• Keyboard / Mouse Connection
• The ultimate in program editing
• Point and Click Menu Navigation
• IRDA Communication Port
– Fast cable-less file transfer to a Computer /
Palm (PDA) and between multiple Robots
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Software and Networking Robots Now and in the Future
Management Information System
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Robots networked Via Ethernet to a
Centralized Data collection base.
Automatic Back-up of Robot Data
SPC – Staticial Process Control
Data that is collected can be measured
against criteria to determine in/out of
specification through UCL /LCL to monitor
out of control processes.
Automatic alert via pagers or e-mail
systems.
Can be configured to auto alert personnel
if, for example, a robot drops down below
90% utilization for a given time interval.
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Software and Networking Robots Now and in the Future
Process Documentation
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The ability at a specified
time interval to extract
pertinent data from the
robot and the welder and
archive that data to be used
later.
Monitors Welding variables
and archives the information
into a database.
Information like actual
amps/volts, programmed
travel speed, step numbers,
time/date stamp, etc can be
archived.
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Software and Networking Robots Now and in the Future
Next Generation of Networking Software
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Interfacing with 3rd party high end weld arc monitors, or Vision
Inspection Systems.
Interfacing with bar code readers for operator
identification for cell access and security or for part traceability.
System monitoring of data devices outside of the robot world,
I.e. plc’s, arc monitor, etc.
Real time intervention of the welding process based on process
information that is being gathered and analyzed based on
previously input decision criteria.
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Software and Networking Robots Now and in the Future
Inspection and Weld Control
Canadian Welding Association October 22, 2002
Sensor
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Software and Networking Robots Now and in the Future
Inspection and Weld Control
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Software and Networking Robots Now and in the Future
Off Line Software-Graphical Programming Tool
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Prototype Process development( Amps, Volts, Speed, Torch angles)
can be quickly and accurately implemented into production
programs
Pre-production cycle time optimization for line balancing
Provides supervisors with a tool to determine if the operators have
modified programs
Part orientation can be checked for cycle time analysis
Sequences of welds can be changed to improve cycle time
Correct robot type and its orientation can be optimized before jigs
and mounting are fabricated
Simplifies cell “cloning”
Will permit off line calibration and drop in of new robots even if the
TCPs are different- Quicker exchange of robots in emergencies
Canadian Welding Association October 22, 2002
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Software and Networking Robots Now and in the Future
New Types of Software in Welding Robotics
Provides the Following;
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Arc Performance
Flexibility for programming
Simplified and lower cost teaching systems
Networking into overall manufacturing systems
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