Software and Networking Robots Now and in the

Software and Networking Robots Now and in the Future Martin M. Weir / Kevin Pagano Panasonic Factory Automation October 22 nd 2002 Canadian Welding Association October 22, 2002 1

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 • Canadian Welding Association October 22, 2002 2

Software and Networking Robots Now and in the Future WELDING EQUIPMENT SOFTWARE n PAST AND PRESENT TECHNOLOGY w SET WIRE FEED SPEED (AMPS) w SET AVERAGE VOLTAGE w LIMITED ARC CONTROL BY HARDWARE n PRESENT AND FUTURE TECHNOLOGY w OPERATOR SETS VOLTAGE AND WIRE FEED SPEED (AMPS) n THEN THE WELDER SOFTWARE SETS n PEAK CURRENT n BASE CURRENT n PULSE FREQUENCY n CURRENT RISING/FALL TIMES AND RATES n SHORT CIRCUITING VARIBLES IN CV MODE Canadian Welding Association October 22, 2002 3

Software and Networking Robots Now and in the Future WELDING EQUIPMENT SOFTWARE n ARC COMMUNICATION w ARTIFICIALLY INTELLIGENT (A. I. ) POWER SUPPLIES CAN COMMUNICATE TO THE ARC WITH REAL TIME FEEDBACK. w HIGH SPEED TRANSISTORS COMBINED WITH REAL TIME FEEDBACK INSURES THAT SOFTWARE INSTRUCTIONS ARE CARRIED OUT. w A. I. POWER SUPPLIES HAVE AN INTERNAL DATA BASE THAT PROVIDES THE INTERACTION OF THE WELDING POWER SOURCE PROCESS VARIBLES. w A. I. POWER SUPPLIES USE SOFTWARE TO SEPARATE THE WELDING ARC INTO THREE SPECIFIC AREAS: Canadian Welding Association October 22, 2002 4

Software and Networking Robots Now and in the Future THREE SPECIFIC AREAS Welding A Starting Finishing M P S TIME Canadian Welding Association October 22, 2002 5

Software and Networking Robots Now and in the Future Software Controlled Arc Start CONVENTIONAL INVERTER Canadian Welding Association October 22, 2002 A. I. INVERTER 6

Software and Networking Robots Now and in the Future STEADY STATE PULSING 90%Ar 10%CO 2 210 Amps. 320 IPM, 23 Volts CONVENTIONAL INVERTER Canadian Welding Association October 22, 2002 A. I. INVERTER 7

Software and Networking Robots Now and in the Future STEADY STATE PULSING 90%Ar 10%CO 2 210 Amps. 320 IPM, 23 Volts (welding over tack) CONVENTIONAL INVERTER Canadian Welding Association October 22, 2002 A. I. INVERTER 8

Software and Networking Robots Now and in the Future Software Controlled Arc End CONVENTIONAL INVERTER Canadian Welding Association October 22, 2002 A. I. INVERTER 9

Software and Networking Robots Now and in the Future WELDING EQUIPMENT TO ROBOT w PAST AND PRESENT TECHNOLOGY n n INTERFACE UNIT REQUIRED BETWEEN ROBOT AND WELDER: n ANALOG SIGNAL FOR WIRE FEED SPEED / VOLTAGE LIMITED CONTROL DO TO HARDWARE CONSTRAINTS. w PRESENT AND FUTURE TECHNOLOGY n § § § 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 Canadian Welding Association October 22, 2002 10

Software and Networking Robots Now and in the Future n FULLY DIGITAL WELDING SYSTEM w w w 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. Canadian Welding Association October 22, 2002 11

Software and Networking Robots Now and in the Future ROBOT SOFTWARE TO THE OPERATOR n PAST AND PRESENT TECHNOLOGY w TEACH PENDANTS (PRIMARY USER INTERFACE) n n n 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 12

Software and Networking Robots Now and in the Future PRESENT AND FUTURE TECHNOLOGY n TEACH PENDANTS w WINDOWS INTERFACE n “USER FRIENDLINESS” w LARGER DISPLAY WITH COLOR n w w SPLIT SCREEN CAPABILITIES FONT SIZE SELECTION MORE INFORMATION DISPLAYED ON PENDANT INCREASED PROGRAMMING CAPABILITIES UNLIMITED FUTURE POSSIBILITIES Canadian Welding Association October 22, 2002 13

Software and Networking Robots Now and in the Future n Windows CE Operating System n ICON BASED n VISUAL n Color Graphics n Canadian Welding Association October 22, 2002 14

Software and Networking Robots Now and in the Future Improved “User Friendliness” Window Functions such As: n n n Copy, Cut, Paste Find Replace Save As Help Canadian Welding Association October 22, 2002 15

Software and Networking Robots Now and in the Future Off-line Editing Pendant n n n Edit programs from the comfort of your office. Same TP as that used in production PC based Robot Simulator w Connect to your PC with actual teach pendant n True off-line training system w Hands on experience without having to purchase an additional robot w Develop technicians without stopping production n Develop programs off-line w Debug program logic w Develop new programs for upcoming jobs w Add comments to existing programs Canadian Welding Association October 22, 2002 16

Software and Networking Robots Now and in the Future Increased Programming Power n n Updated Command Structure Math Functions Configuration Capabilities Connectivity Canadian Welding Association October 22, 2002 17

Software and Networking Robots Now and in the Future ROBOT NETWORKING COMMUNICATIONS n PAST AND PRESENT TECHNOLOGY MANIPULATOR CONTROLLER WELDER PLC Canadian Welding Association October 22, 2002 LIMIT SWITCH 18

Software and Networking Robots Now and in the Future ROBOT NETWORKING COMMUNICATIONS n PRESENT AND FUTURE TECHNOLOGY ETHERNET ISDN PLC Ｐ DEVICENET SENSOR Canadian Welding Association October 22, 2002 19

Software and Networking Robots Now and in the Future Through the power of Windows CE n Access production schedules n Upload/Download programs from server n Share files between Robot cells n Remote servicing via Internet Connection n Production log book on the Teach Pendant n n 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 Canadian Welding Association October 22, 2002 20

Software and Networking Robots Now and in the Future n Unlimited Connectivity n 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 • PS 2 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 Canadian Welding Association October 22, 2002 21

Software and Networking Robots Now and in the Future Management Information System n n n 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. Canadian Welding Association October 22, 2002 22

Software and Networking Robots Now and in the Future Process Documentation n 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. Canadian Welding Association October 22, 2002 23

Software and Networking Robots Now and in the Future Next Generation of Networking Software n n Interfacing with 3 rd 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 analyzed based on previously input decision criteria. Canadian Welding Association October 22, 2002 24

Software and Networking Robots Now and in the Future Inspection and Weld Control Canadian Welding Association October 22, 2002 Sensor 25

Software and Networking Robots Now and in the Future Inspection and Weld Control Canadian Welding Association October 22, 2002 26

Software and Networking Robots Now and in the Future Off Line Software-Graphical Programming Tool n n n n 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 27

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 Canadian Welding Association October 22, 2002 28