Motoman Controller HyperStart User Manual 2018-12-10آ  Motoman, Incorporated 805 Liberty Lane West...

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Transcript of Motoman Controller HyperStart User Manual 2018-12-10آ  Motoman, Incorporated 805 Liberty Lane West...

  • Motoman Controller

    HyperStart User Manual (MRC-DX100 Controllers)

    Part Number: 148375-1CD Document Version: 5

    Motoman, Incorporated 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-Hour Service Hotline: (937) 847-3200

  • The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,

    Inc.

    ©2005 by MOTOMAN All Rights Reserved

    Because we are constantly improving our products, we reserve the right to change specifications without notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

  • HyperStart 148375-1

    Abstract

    This is the preliminary copy of the HyperStart User Manual.

    Document Control Sheet

    Table 1 Document Control Sheet

    Document Title: User Manual HyperStart

    Version: 2

    Issue: 1

    Edition: English

    ID: 148375-1

    Status: Final

    Created: August 13, 2003

    Date: May 24, 2005

    Keywords: arc welding, software

    Tools DTP System: Adobe FrameMaker Version: 7.0

    Layout Template:

    Motoman Manual Template Version: V2.0 - 5 July 1999

    Authorship Written by: Paula Copeland

    Reviewed by: Jason Young, Chris Anderson

    Edited by: Paula Copeland

    Approved by: Sally Fairchild

    Final

  • User Manual Document Status Sheet

    Document Status Sheet

    Document Change Record

    Table 2 Document Status Sheet

    Title: User Manual HyperStart

    ID: 148375-1

    Version Issue Date Reason for change

    2 0 2/9/04 Corrected Appendix

    Table 3 Document Change Record (of changes made since version ... )

    Title: User Manual HyperStart

    ID: 148375-1

    Version: 1 Originator: G.Hxxx

    Date: 22 April 2003 Approved By: I.Jxxx

    Page Paragraph Reason for Change

    Final

  • HyperStart 148375-1

    Table of Contents

    Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

    1.1 HyperStart Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Cycle Time Savings Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.3 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.4 Reference to Other Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.5 Customer Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    Chapter 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

    2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 Standard Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.3 General Safeguarding Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.4 Mechanical Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.5 Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.6 Programming Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.7 Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.8 Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

    Chapter 3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

    3.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.2 HyperStart Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.3 Related Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.4 HyperStart Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

    3.4.1 HyperStart for NX/DX - Static Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.4.2 HyperStart for XRC with Macro Function- Static Start . . . . . . . . . . . . . . . . . . . . . . . . . 18 3.4.3 HyperStart for XRC without Macro Function - Static Start . . . . . . . . . . . . . . . . . . . . . . 19 3.4.4 HyperStart for MRC - Static Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.4.5 HyperStart for NX/DX - Dynamic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.4.6 HyperStart for XRC - Dynamic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3.4.7 HyperStart for XRC without Macro Function - Dynamic Start . . . . . . . . . . . . . . . . . . . 23 3.4.8 HyperStart for MRC - Dynamic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.4.9 HyperStart for NX/DX - Enabling “WLD DONE = RBT MOV” w/ “Static Start” . . 26 3.4.10 HyperStart for NX/DX - Disabling HyperStart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

    Final page i

  • User Manual Table of Contents

    Chapter 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

    Appendix A I/O Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

    page ii Final

  • HyperStart 148375-1

    Chapter 1

    Introduction

    1.1 HyperStart Overview

    Motoman's HyperStart software function offers a variety of benefits, including reduced cycle time, reduction in weld build-up at start of weld, and better detection of missed arc welds. This function allows users to specify parameters critical for controlling the start and end timing of each weld. HyperStart parameters can used globally or changed from weld to weld. HyperStart is available for MRC, XRC, NX100, and DX100 generation controllers and typically functions independent of the welding power supply.

    The MRC and earlier XRC versions of HyperStart allow the user to configure five welding parameters (four timers and one counter) for their welding application. These parameters values are set in Teach mode using the I/O registers. Changes to the various parameter values can only be performed in Teach mode. However, once set, these five welding parameters can be toggled On or Off at any point in the robot job.

    Later versions of the XRC, and all versions of the NX/DX, allow the welding parameters to be changed using the “R*-Hyper” macro command. This macro command allows the user to change parameter settings at any point within a robot job. Each robot has its own set of HyperStart settings so the parameter settings for Robot 1 can be totally different than those used on Robot 2. This provides additional flexibility as weld length, part fit-up, and weld quality demands change.

    The NX/DX uses two aditional parameters to provide easier enabling and disabling of the HyperStart function along with a new feature that ensures that the weld is completed and the arc has been extinguished before the robot is allowed to move away from the ARCOF point. Features:

    • Significant cycle-time savings in applications with numerous welds.

    • Single instruction (XRC, NX/DX) or output (MRC) changes all starting and ending parameters.

    • “Dynamic Arc-Starting” reduces cycle time and excessive weld build-up at start of weld by keeping the robot moving while starting the arc.

    • “Static Arc Starting” provides consistent bead length while still saving cycle time at the end of the weld.

    • Robot retry function continues to work when using “Static Arc-Starting” (does not with “Dynamic Arc-Starting”).

    Final page 1

  • User Manual Chapter 1 Introduction

    • Better detection of arc faults with “Arc Outage Time” and “Arc Outage Counter” parameters.

    • Independent settings for each robot in multi-robot applications.

    • Includes “Weld-In-Teach” feature for program verification.

    • NX/DX version “WLD DONE = RBT MOV” parameter, ensures robot does not move until arc is extinguished.

    1.2 Cycle Time Savings Analysis

    Cycle time savings might vary by a few tenths of a second per weld, depending on a particular power supply's ending routine. HyperStart’s programm