RoboCell and Cell Setup Setup and Operation

Program Environments Machines CIM Machining Cell Setup RoboCell CellSetup – Virtual Cell Construction – Bring in and setup Robot, Equipment, Furniture, and Material. Determine Sizes, and Locations for each. Setup controller Inputs, Outputs, and Peripherals. RoboCell – Manipulate / Operate Imported Virtual Cell, set positions for Robot and Peripherals, Design, Construct and Verify Programming Project Lead The Way, Inc. Copyright 2008

Navigation – Virtual Cell Environment Machines CIM Machining Navigation – Virtual Cell Environment Zoom and Rotate Hold the right mouse button Slide side to side to rotate environment Slide up and down to zoom in and out Tilt Slide the vertical scroll bar on the right hand side up and down to tilt the environment Pan Redirect Camera Top View Pan – Left click and hold to slide the environment without changing zoom, tilt, or rotation Redirect camera – re-center screen on left mouse click on cursor Top View – Reset view to top view Project Lead The Way, Inc. Copyright 2008

Cell Setup Virtual Cell Setup Machines CIM Machining Programs Cell Setup Virtual Cell Setup Standard Toolbar Brining in New Objects Setting Up Connections Editing Existing Objects Showing Work Envelope Work Cell Example Project Lead The Way, Inc. Copyright 2008

Programs RoboCell Programming Programming Example Machines CIM Machining Programs RoboCell Programming Defining Robot Positions Relative Example Program Window Using Work Space Dialog Bars Calculating Roll Program Windows Standard Toolbar Manual Movement Import and Control 3D Model Teach Positions Programming Example Project Lead The Way, Inc. Copyright 2008

Programs RoboCell - Welding Weld Materials and Setup Weld Types Weld Settings Controller Setup Welding Features Welding Analysis

Cell Setup Standard Tool Bar Machines CIM Machining Cell Setup Standard Tool Bar Show Positions Delete Objects Show Names Drag Objects New Object Controller Setup Save File Open File Redirect Camera New File Drag Frame Top View Project Lead The Way, Inc. Copyright 2008

Bringing in New Objects Machines CIM Machining Bringing in New Objects Project Lead The Way, Inc. Copyright 2008

New Objects Menu Machines CIM Machining ER 9u ER 2u ER 4u Peripheral Axes – Controller conations two optional peripherals The following Peripherals are driven by servo motors and can be stopped at any given position or can be controlled be separate sensors Slidebase and Linear Table – Used to index or move material along a linear axis. - Uses one optional peripheral Rotary Table – Used to index material around a circular axis. - Uses one optional peripheral Conveyor – Used to transport material along a linear axis. - Uses one optional peripheral XY Table – Used to index material along the X and Y axis. – Uses both optional peripherals I/O Devices – Controller contains eight inputs and eight outputs Experiment Table – Contains four Momentary switches / inputs, one buzzer / output, and one light / output Sensor – Used to control various devices or provide feedback when material or motion is present – Can be set to see specific materials or colors Project Lead The Way, Inc. Copyright 2008

New Object Menu Machines CIM Machining Project Lead The Way, Inc. Storage Devices Note: The following two devices must be loaded / primed with one part in CellSetup. One part is to be place on grey square of the device Gravity Feeder – Contains a sensor at the bottom of feeder to indicate feeder is empty. User can control quantity of parts contained in feeder Feeder – Pneumatic Feeder – In order to operate the feeder, the program must turn on an output connected to the device in order to push out a new part. The program will then turn off the same output to retract the pneumatics pusher in order to prepare for the next part. A sensor is also present inside the device to indicate the feeder is empty. User can again control the quantity of parts initially in the feeder. (Note: When the virtual cell is imported into RoboCell the part placed on the device will disappear and be pulled into the device waiting to be pushed out. Note: The following Storage devices have no inputs or setting the only used to indicate positions for finished material storage Jig – Used for precision pick and place Template - May be picked up and carried by the robot by the dark grey handle. Typically stored on the ASRS and placed / transported for filling onto the Rack or Buffer Rack, Buffer – Used to hold material or template until machining, assembly, processing is complete ASRS – Used to store 4 or 6 Templates for storage and retrieval Bin – Used to store finished products Machines Mill - Input – Busy / Output – Door, Vise, Cycle Lathe - Input – Busy / Output – Door, Chuck, Cycle PLM1000 – Mill – Input – Busy / Output – Vise, Cycle – No controllable door / shield PLT3000 – Lathe – Input – Busy / Output – Door, Chuck, Cycle Project Lead The Way, Inc. Copyright 2008

New Objects Menu Machines CIM Machining Jig A – T-Joint Welding Tools – See Welding Examples ButtJoint and Tjoint – C:\Program Files\Intelitek\RoboCell\Projects\ER4u Gun Stand – Used to hold MIG torch – Picked straight up out of the holder by the grey handle Welding Jig A – Used to index 2 Welding Plates to weld a T-Joint Welding Jig B – Used to index Welding Materials for process such as a Butt-Joint – Joint is to be centered over the light grey area Welding Materials – Used to show / simulate welding process – MIG wire will build / stack up on material to illustrate welds Jig B – Butt-Joint Project Lead The Way, Inc. Copyright 2008

New Object Menu Machines CIM Machining Project Lead The Way, Inc. Materials Cube, Cylinder, and Ball are used for simulates material transportation throughout a cell – Pick and Place / Palletizing and Stacking – Sizes, materials and colors are customizable – Sensors can be set to see all or specific material and color settings Part 1-4 are used to illustrate machining – Sizes are predetermined by software Purple cylinder can be used to illustrate a machine part from the PLT3000 – Part will go into the machine raw and appear machined as it leaves the machine Red Cube can be used to illustrate a machined part from the PLM1000 - Part will go into the machine raw and appear machined as it leaves the machine Note: Cube and Cylinder can also be used to illustrate machining – Material color will lighten after the machining process is complete Project Lead The Way, Inc. Copyright 2008

Controller Setup Machines CIM Machining Inputs 1-8 Outputs 1-8 Peripherals 1-2 Controller setup is used to arrange the virtual set of connections for the sensors, devices, and machines to the controller box The controller setup is divided into 3 tabs Inputs, Outputs, and Peripherals Project Lead The Way, Inc. Copyright 2008

Controller Setup Setup as New Object are places Setup by selecting the controller icon Drag and drop connections from Not Connected to desired controller number

Editing Existing Objects Show Objects Names Show Objects Coordinates Delete Object Move Object Double click on any object to see attributes that can be changed Name Rotate Size Position Machine Settings

Machines CIM Machining Showing Work Envelope Double click on the robot to choose show envelop option Work Envelope – The limits in which the robot can operate Project Lead The Way, Inc. Copyright 2008

Work Cell Example Start new CellSetup Create an new empty cell Select Robot ER 4u

Setup Environment Bring in a new robot with no slidebase Create a new table 1000mm x 1000mm &place it under the robot

Navigate and Orientate Use the vertical scroll bar, right mouse, redirect camera, and pan to adjust the camera angle and position

Move Objects in the Cell Move the table around the cell until robot is properly positioned on the table

Bring in Material Bring in three Cubes 40mm x 40mm x 40mm Place the cube in front of the robot Double click on the robot and turn on the work envelope

Adjust Material Placement Precision Input Turn on show positions - Ensure cubes are inside work envelope Double click on the center cube Change position X 300mm (In and Out) Y 0mm (Side to Side)

Adjust Material Placement Precision Input Change the position of the outside blocks Positive/Right Negative/Left X 300mm X 300mm Y 150mm Y -150mm

Input / Output Device Experimental Table Insert experimental table X 0.0mm Y 350mm Rotation 0.0 degrees

Finish Cell Save the Cell Input 3 Input 4 Output 1 Lamp Input 2 Buzzer

Standard Toolbar New File Open File Save File Run Single Cycle Machines CIM Machining Standard Toolbar New File Open File Save File Run Single Cycle Search Home All Axes Level 1 Level 2 Level Pro Run Single Line Control On Pause Cycle Run Continuously Stop Cycle Control Off Charts Window Search Home All Axes – Used outside of the virtual environment to Home the actual robot Control On and Off – Turns on the communication between the actual robot controller and the computer. Enable or Disables servo control of the axes. When control is off, axes cannot be moved. Pause Cycle – Only active will a cycle is in progress. Stops program execution after the current line is executed. Charts Window – Records encoder information Level 1 – Level Pro – Changes programming option from simple to advanced – Introductory, advanced, and professional Run Continuously – Will restart the program after the last line Run Single Cycle – Will stop the cycle at the end of the program unless the program is set to loop internally Run Single Line – Will run one line of programming at a time – Used typically for program troubleshooting Stop Cycle – Will stop any initiated cycle Project Lead The Way, Inc. Copyright 2008

RoboCell Programming Windows Machines CIM Machining RoboCell Programming Windows 3D Image Positions Standard Toolbar Program Programming Windows can be opened, arranged and closed be each user in any configuration and size Each user can choose which windows and dialog bars to view Expanded Teach Positions Robot Movement Manual Movements Dialog Bars Workspace Project Lead The Way, Inc. Copyright 2008

Manual Movement Machines CIM Machining Joints Input XYZ Movement Open Gripper Close Gripper Movement Type Movement Speed 1 2 3 4 5 6 Movement Dialog Boxes – View – Robot Movement Manual Movement Joints – Enables individual joint movement Waist 1-Right Q-Left Shoulder 2-Back W-Forward Elbow 3-Up E-Down Wrist 4-Up R-Down Wrist 5-CCW T-CW Gripper 6-Open Y-Close Incremental Axis 7 +7 -U Axis 8 +8 -I XYZ – Moves Multiple Joints Simultaneously – Movement is based maintaining gripper center orientation X +1 -Out -Q -In Y +2 -Right -W -Left Z +3 -Up -E -Down P-Rotate +4 -Up -R -Down R-Rotate +5 -CW -T -CCW Project Lead The Way, Inc. Copyright 2008

Import 3D Image Machines CIM Machining Project Lead The Way, Inc. Bring in CellSetup Simulation Cell File - Import 3D Model Edit CellSetup Simulation Cell File – Edit 3D Model Control Simulation Settings with 3D Image Pull-Down Options Attach Image to RoboCell File and save window configurations Project Lead The Way, Inc. Copyright 2008

3D Image Redirect Camera Follow Me Top View Send Robot to Object Machines CIM Machining 3D Image Redirect Camera Follow Me Top View Send Robot to Object Save Camera Position Show Object Names Show Object Positions Drag Image Send Robot to Point Clear Robot Path Show Robot Path Reset Cell Send Robot Above Point Reset Cell – Resets the virtual cell Redirect Camera – re-center screen on left mouse click on cursor Follow Me – Allows the camera to follow any object selected – If gripper is selected, gripper will remain centered on the screen during robot movements Drag Image – Pan / Left click and hold to slide the environment without changing zoom, tilt, or rotation Top View – Reset view to top view Save Camera Position – Resets saved camera view from CellSetup Show Object Names and Positions – Visually displays names and or positions near each individual object Clear and Show Robot Path – Leaves a visual trail of robot gripper movement Manual Movements Send Robot to Object - Sends the robot to the selected object. Make sure the gripper is open before sending the robot to the object. This option is useful for defining a robot pick position. Send Robot to Point - Sends the robot to the selected point. This option is useful for defining a robot place position. Send Robot to Above Point - Sends the robot to a point above the selected point on the table. Default: point 100 mm above the selected point. Project Lead The Way, Inc. Copyright 2008

Send Robot Settings 3D Image Send Robot Send Robot Settings Machines CIM Machining Send Robot Settings 3D Image Send Robot Send Robot Settings Send Robot Settings - Opens the Send Robot Options dialog box enabling you to define the vertical offset values and the gripper’s orientation when Send Robot commands are executed. Project Lead The Way, Inc. Copyright 2008

Teach Positions Simple Machines CIM Machining Teach Positions Simple Go to Recorded Position Position Number Included Axes Record Current Position Teach Positions Dialog Box – View & Teach Positions Position Number – User generated numbers for recalling recorder positions Included Axes – Positions can be recorded with data from robot and or peripherals – All peripherals use servo motors which can be driven to specific locations Go to Position – Takes a curved path to travel from the current position to the position present in the Position Number window Speed / Duration – Sets a speed from 1 to 10 or a duration in seconds for the Go to Position command Coordinate Type – Allows the user to record the current robot position in absolute coordinate or relative to the coordinates of another position Delete Position – Allows the user to remove / delete a recorder position form the list of recorder positions Expand – Expands the Teach Positions window to show advanced position options Record Current Position – This command will record the positions for each stepper motor chosen (Robot / Peripherals) for the provided position number Coordinate Type Speed / Duration for Manual Movement Expand Teach Positions Delete Recorded Position Project Lead The Way, Inc. Copyright 2008

Teach Positions Expanded Machines CIM Machining Teach Positions Expanded Go Circular to Recorded Position Teach Position with Relative Coordinates Circular Position Get Position Go to Recorded Position Position Number Go Circular to Position – Sweep to one position via another position – allows for a smoother transition for sharp turns or complex joint movements Go Linear to Position – Move in a straight line between two points Get Position – will find all five current coordinates for the robot gripper Clear – Will clear all five coordinates to 0 Teach – Will record specific coordinates both absolute and relative to the provided position number Go Linear to Recorded Position Relative to Coordinate Shrink Teach Positions Project Lead The Way, Inc. Copyright 2008

Program Window On Input Interrupt If Input Turn On Output Set Variable Machines CIM Machining Program Window Close Gripper Go to Position Go Circular to Position If Condition Jump to Go Linear to Position Set Variable Turn On Output Turn Off Output Open Gripper If Input On Input Interrupt Quick Programming Commands Project Lead The Way, Inc. Copyright 2008

Program Window Go to Position Machines CIM Machining Program Window Go to Position Go to Position Go Linear to Position Go Circular to Position Go to Position – Takes a curved path to travel from the current position to the position present in the Position Number window Go Circular to Position – Sweep to one position via another position – allows for a smoother transition for sharp turns or complex joint movements Go Linear to Position – Move in a straight line between two points Project Lead The Way, Inc. Copyright 2008

Program Window If Condition Machines CIM Machining Program Window If Condition If Condition Jump to (or jump to) – If set condition is met, jump to program label – Ex: if Variable X = 3 Jump to STOP If Input – If an input is on or off jump to label or call subroutine On Input Interrupt - If an input is on or off call or run subroutine - handles responses to changes in digital input status. Input Interrupt It sets the condition for an input interrupt service. The service (Call Subroutine) will be performed whenever the condition (input status) is satisfied, regardless of the current program flow. This means that the system will continuously check the sensor (input terminal) until a signal is received. Once the signal is received, the program will abandon the command currently being executed and immediately execute the command specified for this interrupt instead. The program will resume from the point where it was interrupted as soon as the subroutine completes its execution. When working with the On Input Interrupt#_On command, you must also add the following pair of commands to your program: ♦ Disable Interrupt #_: This command causes the specified input interrupt to become inactive. ♦ Enable Interrupt#_: When an interrupt is disabled, it is disregarded until this command reactivates it. Project Lead The Way, Inc. Copyright 2008

Program Window Set Variable Machines CIM Machining Program Window Set Variable Options Set Variable - Allows a variable to be set by: Computation Time in Seconds (1/10 sec) Gripper Sensor in mm Analog Input Joint Value at Position in deg or mm (1/100 of deg) Cartesian Coordinate at Position in deg or mm (1/100 of deg) Project Lead The Way, Inc. Copyright 2008

Using Work Space Machines CIM Machining Project Lead The Way, Inc. Commands Available Depend on Level of Programming Selected Project Lead The Way, Inc. Copyright 2008

Work Space – Axis Control

Work Space – Program Flow

Work Space - Inputs and Outputs

Dialog Bars Machines CIM Machining Project Lead The Way, Inc. Dialog Bars provide information about the status of: Joints XYZ Digital Inputs and Outputs – Lighted-On / Dark-Off Right Click on an individual Input or Output to force a change in value Analog Inputs and Outputs Encoder Counts Project Lead The Way, Inc. Copyright 2008

Defining Robot Positions Machines CIM Machining Defining Robot Positions Recording Position Method #1 Manually Move Robot Create a New Position # Click Record Use the Manual Movement dialog box to manipulate the virtual robot in the same manner in which you would manipulate an actual robot. When the position is reached, type a number in the position number field in the Teach Position (Simple) dialog box. Click Record. If the position number has been used previously, the new position will overwrite the previous position data Click Record or Teach to overwrite the previous position. Project Lead The Way, Inc. Copyright 2008

Defining Robot Positions Machines CIM Machining Defining Robot Positions Recording Position Method #2 Use Send Robot to Object Position Above Position Manually Move for Fine-Tuning if Necessary Create a New Position # Click Record To send a robot to a required position, use the Send Robot to Object/Position/Above Position tools. If needed, use the Manual Movement dialog box for fine-tuning. When the position is reached, type a number in the position number field in the Teach Position (Simple) dialog box. Click Record. If the position number has been used previously, the new position will overwrite the previous position data. Project Lead The Way, Inc. Copyright 2008

Defining Robot Positions Machines CIM Machining Defining Robot Positions Fine-Tuning a Position Modifying Current Positions Manually Fine-Tune Robot and Re-Record Position Get Position for Current Gripper Coordinates or Position Alter Dimensions and Re-Teach To modify existing positions: Click Teach Position (Simple) Expanded to open the Teach Position dialog box. Select the position you want to modify in the Position Number field. Click Get Position. The position data appears in the X, Y, Z, P, and R fields. Modify the required coordinate. Click Teach to overwrite the previous position. Project Lead The Way, Inc. Copyright 2008

Defining Robot Positions Machines CIM Machining Defining Robot Positions Teaching Position In the Graphic Display window, select View | Show Positions to see the X and Y coordinates of an object. Zoom in on the object or point whose coordinates you want to record. Click the Teach Position (Simple) Expanded button to open the Teach Position dialog box. Type the position coordinates in the X, Y, Z, P, and R fields. (Note: Z for a Pick position is typically 10mm and R (Roll) is 0mm) (P (Pitch) must be calculated for desired angle) Enter a number in the position number field. Click Teach. To record the coordinates from the manual inputs, the user must use the teach command to the record. Turn on X and Y Coordinates Expand the Teach Positions Dialog Type in Desired Coordinates Create a New Position # Click Teach Project Lead The Way, Inc. Copyright 2008

Defining Robot Positions Relative Positions Expand the Teach Positions Dialog Create a New Position # Select Relative to Current Position Another Position # Type in Desired Relative Coordinates for New Positions (Note: Coordinates that do not change Leave 0 Click Teach

Defining Robot Positions Relative Positions Example #1 Move Center Cube Back to 100.0, 0,0 with a hover of +60mm Open Gripper Send to Object Record Position as Absolute 1

Defining Robot Positions Relative Positions Example #2 X Y Original Block (Red) 300mm, 0mm Create New Position 2 Select Relative to Position 1 Change Z (mm) to +60 Select Teach 60mm 1 2 3 4 - +

Defining Robot Positions Relative Positions Example #3 Original Position (Red) +300.0mm, 0mm Create New Position 3 Select Relative to Position 2 Select Clear Change X (mm) to -100 ( +300.0mm Original - +200mm New = 100) Select Teach 1 2 3 4 100mm - +

Defining Robot Positions Relative Positions Example Create New Position 4 Select Relative to Position 1 Keep X (mm) -100 Select Teach 60mm 1 2 3 4 - +

Defining Robot Positions Calculating Roll Pitch 4 & R Roll 5 & P

Calculating Roll 280 mm 120 mm 100 mm θ1 θ2 -120 mm

Solving for θ1 θ1 Opposite = -120 Adjacent = 280 tanθ1 = -120/ 280 toa = tanθ1 = Opposite/Adjacent Opposite = -120 Adjacent = 280 tanθ1 = -120/ 280 tanθ1 = -0.429 θ1 = tan-1(-0.429) θ1 = -23.2º Roll1 = -23.2º Pitch = -90º -120 mm 280 mm (- Left Side / + Right Side)

Solving for θ2 Opposite = _____ θ2 Adjacent = _____ 100 mm θ1 θ2 -120 mm toa = tanθ2 = Opposite/Adjacent Opposite = _____ Adjacent = _____ tanθ2 = _____ / _____ tanθ2 = _____ θ2 = tan-1(_____) θ2 = _____º Pitch = -90º

Solving for θ2 Opposite = -120 Adjacent = 100 θ2 tanθ2 = -120 / 100 100 mm -120 mm toa = tanθ2 = Opposite/Adjacent Opposite = -120 Adjacent = 100 tanθ2 = -120 / 100 Tanθ2 =-1.2 θ2 = tan-1(-1.2) θ2 = 50.19º Roll2 = -50.19º Pitch = -90º (- Left Side / + Right Side) θ2 θ1

Programming Example Start new RoboCell Create an new file Import 3D Model

Turn on Digital Inputs & Outputs Setup Work Area Turn on Digital Inputs & Outputs Set Level to Pro Save User Screen

Find and Record/Teach Positions 10 11 20 21 30 31 40 41 Home 1 Place Hoover Absolute and/or Relative Positions Manual Movements 2

Develop Program Experimental Table Feedback Movements Output 1 – Lamp Output 2 – Buzzer Input 1 – Station 30 Input 2 – Station 40 Feedback -Turn on Lamp While Robot is in Motion -Turn on Buzzer If Station 30 and 40 are full Movements If Station 1 is Empty Place Block 1 on Station 30 If Station 30 is Full Check Station 40 If Station 40 is Empty Place Block 2 on Station 40 If Station 30 and 40 are Full Wait at Home When Station 30 and 40 are Empty Loop to Beginning

Create Programming Quick Programming Workspace

Program PLACE_40: BEGIN: PLACE_30: UNLOAD: LOOP_WAIT: *Remark: Get block from station 2 - place on station 40 Turn On Output 1 Go to Position 21 Fast Go Linear to Position 20 Speed 5 Close Gripper Go Linear to Position 21 Speed 5 Go to Position 40 Speed 8 Go Linear to Position 41 Speed 5 Open Gripper Go Linear to Position 40 Speed 5 Jump to BEGIN UNLOAD: *Remark: Station 30 and 40 full - wait for unload *Remark: Turn on Buzzer Turn On Output 2 LOOP_WAIT: If Input 2 On Jump to LOOP_WAIT *Remark: Turn off Buzzer Turn Off Output 2 BEGIN: *Remark: Turn off Lamp Turn Off Output 1 Open Gripper *Remark: Move to Safe Position Go to Position 1 Speed 5 If Input 1 Off Jump to PLACE_30 If Input 1 On Jump to PLACE_40 If Input 40 On Jump to UNLOAD PLACE_30: *Remark: Get block from station 2 - place on station 30 Turn On Output 1 Go to Position 11 Fast Go Linear to Position 10 Speed 5 Close Gripper Go Linear to Position 11 Speed 5 Go to Position 30 Speed 8 Go Linear to Position 31 Speed 5 Go Linear to Position 30 Speed 5 Jump to BEGIN

Welding Objects Machines CIM Machining Jig A – T-Joint Jig B – Butt-Joint Project Lead The Way, Inc. Copyright 2008

Welding Setup Record position #1 and #2 Some Weld Joints May Require a Tack Weld For both positions, set the Z coordinate to 60 mm and the pitch to -90°. #1 #2 Tack Welds

Weld – Butt Joint Machines CIM Machining Tack Weld -Linear Weld- Opposite End Back to Tack Weld Turns Grey as it Cools Butt weld: Weld in which the pieces are welded side-by-side. Linear Weld Stack onto Tack Project Lead The Way, Inc. Copyright 2008

Weld – T-Joint Place Part 1 Place Part 2

Build-Up at the End of Weld Machines CIM Machining Weld – T-Joint Build-Up at the End of Weld Weld will build up at the end of a weld due to the pause and time to turn weld off Project Lead The Way, Inc. Copyright 2008

Weld - Text Machines CIM Machining Project Lead The Way, Inc. Letters and numerals: A gun is used to weld letters or numerals on a large metal plate placed on the butt jig. Project Lead The Way, Inc. Copyright 2008

Welding Settings Welding Settings Dialog Box Machines CIM Machining Enables definition of the following weld parameters: • Voltage Tap • Wire Diameter • Wire Speed • Shielding Gas To open the welding machine properties window do one of the following: Select 3D Image | Welding Setting from the RoboCell main menu. Note: The Welding Setting option is only enabled if you have defined a welding machine and a welding gun in the cell. Double click on the welding machine image in the 3D window. Voltage Tap Sets welding machine voltage output supplied to the welding gun, an important variable in determining the quality and appearance of a weld. The voltage tap value is a reference number (and 2 does not indicate a voltage value). The voltage tap should be set according to several factors, such as robot speed, wire speed and metal thickness. Wire Diameter Sets diameter of the welding wire being fed to the MIG welding gun. Cannot be changed. Default of wire diameter used is 0.023 inch. Wire Speed Sets speed at which the wire is fed to the MIG welding gun. Also known as feed rate. The wire speed setting is essentially a reference value to the controller built into the welder. Valid values: 10 - 100. The wire speed is automatically regulated by the welder for optimal performance and does not need manual input. The welder determines the feed rate setting by weighing three factors: type of shielding gas, metal thickness and wire diameter. Shielding Gas Sets type of gas for shielding the weld from oxidation, which causes rust and poor joining of the welded pieces. The system only works with CO2 gas. Project Lead The Way, Inc. Copyright 2008

Welding Controller Setup Machines CIM Machining Welding Controller Setup Set Welding Machine to an Empty Output Controller Output Number for Welding Machine The welding machine operation is controlled using a controller output. After placing the welding machine (in CellSetup) you should assign a free controller output for controlling the welding machine. Project Lead The Way, Inc. Copyright 2008

Built-In Welding Features Machines CIM Machining Built-In Welding Features Wire Speed Voltage Wire Spool Motion During the welding process, the wire spool turns just as it does in reality. Wire Speed, Voltage and Power Switches The knobs on the welder accurately reflect the welding settings defined via the Welding Settings dialog box. Double clicking on any knob opens the dialog box. Wire Spool On / Off Project Lead The Way, Inc. Copyright 2008

Welding Booth Doors Machines CIM Machining Welding Booth Doors The welding booth doors can be viewed or removed by double-clicking anywhere on the booth. Welding Booth Doors Project Lead The Way, Inc. Copyright 2008

Controllable Features Machines CIM Machining Controllable Features Machine Settings Machining Variables Inert Gas Shield None or CO2 Voltage Tap Fan Only, 1-4 Wire Feed Rate Rate of Travel Rate of Travel Distance for Electrode from Material to be Welded Angle of Electrode Inert Gas Shield From the Welding Settings dialog box, select either None or CO2. Voltage Tap From the Welding Settings dialog box, select one of the reference numbers. Wire Feed Rate Automatically changes when voltage tap is changed. Rate of Travel To define the rate of travel (the speed of the robot and the welding gun in the welding procedure), use the Duration setting in the Go To position dialog box. By changing the duration it takes to get from position A (weld start position) to B (weld end position), the robot’s speed is changed – thus changing the speed at which it will weld. Distance for Electrode from Material to be Welded When recording the start/finish welding positions,you define this distance by defining the positions’ Z value. Welding only occurs when the electrode of the welding gun is located at a proper distance above “weldable” material. This feature was built-in to enable more accurate recording of the start welding position. Once the software recognizes that welding is “allowed”, the gun emits wire that creates a seam between the two materials. Welding will not occur in the following situations: The electrode of the welding gun is too close or too far from the material. The welding gun is located above a material that the software recognizes as “non-weldable”. Angle of Electrode When recording the start/finish weld positions, you define this angle by defining the positions’ pitch. Project Lead The Way, Inc. Copyright 2008

Weld Analysis Machines CIM Machining Project Lead The Way, Inc. RoboCell allows you to observe the quality of a weld at the end of the welding process. Depending on the welding settings used to create the weld, the appearances of welds may differ. After welding two metals together, double-click on the seam to open the Weld Properties window. Project Lead The Way, Inc. Copyright 2008