Software and Networking Robots Now and in the Future

1
Software and Networking Robots Now and in the
Future

• Martin M. Weir / Kevin Pagano
• Panasonic Factory Automation
• October 22nd 2002
• Canadian Welding Association

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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
• PAST AND PRESENT TECHNOLOGY
• SET WIRE FEED SPEED (AMPS)
• SET AVERAGE VOLTAGE
• LIMITED ARC CONTROL BY HARDWARE
• PRESENT AND FUTURE TECHNOLOGY
• OPERATOR SETS VOLTAGE AND WIRE FEED SPEED (AMPS)
• THEN THE WELDER SOFTWARE SETS
• PEAK CURRENT
• BASE CURRENT
• PULSE FREQUENCY
• CURRENT RISING/FALL TIMES AND RATES
• SHORT CIRCUITING VARIBLES IN CV MODE

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Software and Networking Robots Now and in the
Future

• WELDING EQUIPMENT SOFTWARE
• 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 M P S
Starting
Finishing
TIME
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Software and Networking Robots Now and in the
Future
Software Controlled Arc Start
A.I. INVERTER
CONVENTIONAL INVERTER
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Software and Networking Robots Now and in the
Future
STEADY STATE PULSING 90Ar10CO2 210 Amps. 320
IPM, 23 Volts
A.I. INVERTER
CONVENTIONAL INVERTER
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Software and Networking Robots Now and in the
Future
STEADY STATE PULSING 90Ar10CO2 210 Amps. 320
IPM, 23 Volts (welding over tack)
A.I. INVERTER
CONVENTIONAL INVERTER
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Software and Networking Robots Now and in the
Future
Software Controlled Arc End
A.I. INVERTER
CONVENTIONAL INVERTER
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Software and Networking Robots Now and in the
Future

• WELDING EQUIPMENT TO ROBOT
• PAST AND PRESENT TECHNOLOGY
• INTERFACE UNIT REQUIRED BETWEEN ROBOT AND WELDER
  
• ANALOG SIGNAL FOR WIRE FEED SPEED / VOLTAGE
• LIMITED CONTROL DO TO HARDWARE CONSTRAINTS.
• PRESENT AND FUTURE TECHNOLOGY
• 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

• FULLY DIGITAL WELDING SYSTEM
• AUTO RECOGNITION OF WELDER
• DIGITAL CALIBRATION
• TOTAL WAVEFORM CONTROL
• CONNECT MULTIPLE WELDERS
• WELDER FRONT PANEL IS INACTIVE OE ELIMINATED
• 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
• PAST AND PRESENT TECHNOLOGY
• TEACH PENDANTS (PRIMARY USER INTERFACE)
• 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

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Software and Networking Robots Now and in the
Future

• PRESENT AND FUTURE TECHNOLOGY
• TEACH PENDANTS
• WINDOWS INTERFACE
• USER FRIENDLINESS
• LARGER DISPLAY WITH COLOR
• 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

• Windows
• 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
• 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
• 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
• True off-line training system
• Hands on experience without having to purchase an
  additional robot
• Develop technicians without stopping production
• 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

CONTROLLER
MANIPULATOR
LIMIT SWITCH
WELDER
PLC
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Software and Networking Robots Now and in the
Future

• ROBOT NETWORKING COMMUNICATIONS
• PRESENT AND FUTURE TECHNOLOGY

ISDN
ETHERNET
P
PLC
DEVICENET
SENSOR
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Software and Networking Robots Now and in the
Future

• Through the power of Windows CE
• Access production schedules
• Upload/Download programs from server
• Share files between Robot cells
• Remote servicing via Internet Connection
• Production log book on the Teach Pendant
• 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

• Unlimited Connectivity
• 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
• 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
• 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
• 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. plcs, 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

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
• 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

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Software and Networking Robots Now and in the
Future

• New Types of Software in Welding Robotics
  Provides the Following
• Arc Performance
• Flexibility for programming
• Simplified and lower cost teaching systems
• Networking into overall manufacturing systems