bochweld

Art.no 3HAC 5745-1 Bosch Weld Timer Interface

CONTENTSPage

1 Introduction .....................................................................................................................5

2 Description .......................................................................................................................6

2.1 Hardware ................................................................................................................6

2.2 Communication ......................................................................................................7

3 Spot Welding with Bosch weld timer by serial link .....................................................8

3.1 IO configuration .....................................................................................................8

3.2 Board configuration................................................................................................8

3.3 Basic physical equipment setup.............................................................................. 9

3.4 Virtual timer setup ..................................................................................................10

3.5 Double gun .............................................................................................................13

3.6 Spot identity............................................................................................................13

Bosch Weld Timer Interface 3

Bosch Weld Timer Interface

Page

4 Bosch Weld Timer Interface

Introduction

1 Introduction

This manual is primarily a description of serial data communication between the Bosch PSS5000/PSS5200 and the ABB Robotics S4/S4C systems. Some of the physical char-acteristics of the Bosch system are also dealt with.

Its should be noted that this is a supplementary manual to the other robot manuals. A more detailed description of the Bosch PSS5000 system will be found in the document “Technische Information PSS5000”.


Description

stant

2 Description

2.1 Hardware

The hardware of the Bosch PSS5000 system comprises a control unit, which together with a power supply unit, forms the core of the ABB Robotics spot-welding system. The front panel of the control unit is shown in Figure 1. Connections to the panel, including communication with the S4 system, are also shown.

Figure 1 Front panel of the Bosch PSS5000

PSS 5000

Connection for earth cable

V24-ABB interface

V24-Bosch “standardinterface”

Connection for protective earth Connections for earth cables(casing)

LED, +24V voltageto control unit, on

LED, power failure/battery empty

RESET button

LED, control signal topower unit active

LED, low battery voltage

Input for monitoring primary voltage of weldingtransformer

Connections for power unit(synchronisation voltage,control and monitoring ofpower unit)

Connections for internalpower supplies (+24V),STOP bridge and +24Vin/out

Sensor connection formeasuring system (e.g “conconstant regulation”)

Analog output for controlof e.g. solenoid valve

Battery box (only forbatteries with Bosch no.1070914446)

Selector switch for settingaddresses in theprogramming interface

LED, control processor not in operational status

Recessed button foroperation/boot position

Connection for mainswitch fuse


Description

In the ABB Robotics application, the control unit Bosch PSS5000 is equipped with a further V24 interface called V24-ABB. This is used to communicate directly with the protocol of the S4 system via the RS232-C interface on the control cabinet. However, the standard interface V24-Bosch has been retained unchanged in this version so that direct PC communication can be used when required.

Remark

The V24-ABB interface is only suitable for short lengths of cable and for connection inside the control cabinet.

Safety

We strongly recommend that you order the earth fault protection unit which is available as an option, or that you fit a similar protection unit in your part of the cabling. The equipment is supplied with an earth rail fitted near the roof inside the control cabinet. Incoming earth cables, which are adapted to this type of current, should be connected to this rail.

2.2 Communication

The Bosch PSS5000/PSS5200 and the robot control system S4 communicate in serial via the V24-ABB interface on the control unit and the RS232-C interface on the control cabinet.

Interface

The interface in the robot system control cabinet is a standard EIA RS232-C with the following characteristics:

• 11 bit characters (1 start bit, 8 data bits, 1 even parity bit, 1 stop bit)

• Transmission rate: 19200 Baud


Spot Welding with Bosch weld timer by serial link

3 Spot Welding with Bosch weld timer by serial link

The S4 SpotWare and S4C SpotWare (NOT S4C SpotWare Plus) is able to communi-cate with the Bosch PSS5000/PSS5200 weld timer connected by a serial link.

By using virtual I/O signals mapping the internal serial commands, the user’s interface to the timer is still presented by parallel I/O.

The spot welding system parameters are defined by both virtual and physical input and output signals.

• Choose Topics: IO

• Choose Types: User Signals

3.1 IO configuration

The SpotWare package can be configured for different equipment setups. This chapter describes the signals used by SpotWare and their dependency of the Bosch PSS5000.

The virtual signals used to communicate with the timer (virtual board type reio) are mapped to internal serial drivers. They have no physical correspondence but they are internally connected to serial communication selectors and shall therefore not be changed.

The physical connections are used for all other equipment. They can be freely changed. To save physical signals, signals not in use can be connected to a virtual board (type eip000).

If different signal names are required, new logical signals can be added and connected to the corresponding physical signal. The predefined logical name must remain in the configuration as it is used internally by the SpotL instruction.

3.2 Board configuration

There are four predefined boards:

-one physical, DSQC 223 board, named SW_BOARD, at address 1. (S4) or-one physical, DSQC 328 board, named SW_BOARD, at address 10. (S4C)

-one virtual, named SIM-BOARD.

-two virtual, named SW_BOS1 and SW_BOS2.

The basic physical setup signals are connected to the SW_BOARD. Physical signals not in use are connected to the SIM_BOARD which makes them easy to activate. Vir-tual signals to the weld timer are connected to SW_BOS1 and SW_BOS2.



3.3 Basic physical equipment setup

Gun control

Pressure setting and supervision

The SpotWare can set and supervise up to four discrete pressure levels. The pressure values are selected in spotdata.The number of possible pressure levels is defined for each gun by nof_plevels in gundata. The corresponding output signals p2_req to p4_req must be defined as consecutive physical outputs. If only one pressure level exists, no pressure request signals need to be connected.

If supervision of the ordered pressure value is required before welding is allowed to start (close_request = TRUE in gundata), this is done on one of the input signals p1_ok to p4_ok depending on the selected pressure value in spotdata.

close_tip1 output 5 Close gun signal. (Tip 1, if a dual gun is used).

work_select output 6 Work stroke select. Default functionality: The sig-nal is set to 1 after the welding if work stroke (small gap) is desired, and is set to 0 if retract stroke (large gap) is desired. When the SpotL instruction orders the gun to close, the work_select is also set. The signal is also set according to the Retract argument in the instruction.

pressure_group output 2-4 p2_req-p4_req

p1_ok input 1 Pressure confirmation signal when gun_pressure 1 is requested in spotdata.




nof_plevels output output group

1 none pressure group (simulated outputs)

2 p2_req pressure group (p2_req)

3 p3_req pressure group (p2_req, p3_req)

4 p4_req pressure group (p2_req, p3_req, p4_req)



Gun opening supervision

If open_request = TRUE in gundata, a check is made whether or not the gun is open before a motion is released.

Process error

Equipment supervision

By default, the following input signals are tested in every welding position before the weld start. If desired, other user defined signals can be tested, before or after the weld-ing process. (See also Predefined Data)

3.4 Virtual timer setup

The signals correspond to those of the Bosch PSS5000 with parallel communication.

Initialization

tip1_open input 5 The gun (tip 1 if a dual gun is used) is open enough to release the robot motion.

tip1_retract input 6 Retract stroke acknowledge. (Not tested in SpotL)

process_error output 9 Operator request is set when an error situation occurs.

flow_ok input 9 Signal indicating problems with the water sup-ply.

temp_ok input 10 Signal indicating over-temperature.

current_ok input 11 Signal indicating that the weld current exceeds the permissible tolerances.

initiate sim output group

Initialization of the Bosch communication. The value represents the polling time of the current Bosch status (>=100ms S4). (40ms (working) - 300ms (idle) S4C) The group is internally used by SpotWare.



Start and monitoring of the weld

Weld program number

N.B. Signals in the same group must be connected to physical signals in sequence on the same board.

Timer reset

Current signal

Service acknowledge

start1 sim output Start signal to the weld timer (Tip1 if a dual gun is used)

weld_ready1 sim input A high signal is obtained from the welding timer when the weld, started with start1, is finished. The signal is expected to be reset by the weld timer when the start signal is reset. If the weld_ready signal is not received within a prede-fined time period, an error message will be dis-played.

prog_no_group sim output group

Weld program number

prog_parity sim output Weld program number parity bit. Not used.

reset_fault sim output Reset signal. Can be used to reset the welding controller after a weld error. The signal is pulsed with a user defined pulse length. (sw_reset_time1) before manual or automatic rewelding.

current_enable sim output Current enable signal. Used for the weld inhibit function. See Predefined Data and Programs (sw_inhib_weld).

tips_dressed sim output group

Acknowledge that tip dressing was done. The group designates the tip number (0-31). Signal is not used by SpotWare.



Equipment supervision

By default, the timer_ready is tested in every welding position before the weld start. If desired, other user defined signals can be tested, before or after the welding process. (See also Predefined Data)

Timer status

This status group shows the timer status code (See Bosch documentation, parallel timer interface).

tips_changed sim output group

Acknowledge that tips were changed. The group designates the tip number (0-31). Signal is not used by SpotWare.

timer_ready sim input The timer is ready to weld.

weld_error sim input The timer has indicated a weld error. Signal is not used by SpotWare.

curr_enabled sim input The timer is in current enable mode. Signal is not used by SpotWare.

no_supervision sim input No timer supervision active. Signal is not used by SpotWare.

dress_request sim input Tip dressing requested by the timer. Signal is not used by SpotWare.

pre_warning sim input Tip life prewarning. Signal is not used by Spot-Ware.

tiplife sim input Request to change tips. Signal is not used by SpotWare.

timer_status sim input group

The timer status.



3.5 Double gun

When a double gun is used, it must be indicated in gundata by nof_tips = 2. Tip_no in spotdata chooses the tip (tip_no = 12 or 21 closes both tips together). Close_tip1, work_select and close_tip2 must be defined as consecutive physical signals.

3.6 Spot identity

The PSS 5000 weld timer is able to execute a weld program on a request from a spot name (string format) instead of using a program number.If spot identity shall be used it has to be indicated with the request flag (sw_spot_id_req) set to TRUE. See Predefined Data and Programs.

Limitation: The spot identity map in the Bosch Timer may only use names of max. 16 character since this is the limit of the S4-data-naming.

Note: The spot identity request flag must be set to TRUE before the welding sequence of a RAPID weld program (with SpotL instructions) has been started.

start2 sim output Not in use for Bosch PSS5000.

close_tip2 sim output Close gun request, tip 2

weld_ready2 sim input Not in use for Bosch PSS5000.

tip2_open sim input Tip 2 is open enough to release the robot motion.

tip2_retract sim input Retract stroke acknowledge. (Not tested in SpotL)


Notes:

ABB Robotics ABDPT / MTS-721 68 VÄSTERÅSSWEDENTelephone: +46 (0) 21 34 40 00Telefax: +46 (0) 21 13 25 92

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