Kuka»Ъжчилєёѕуинјюkuka Arc Tech Analogіщччкціб

SOFTWARE
KR C2
KUKA.ArcTech Analog -- Operation

Arc welding for power sources with analog reference voltage
Release 1.0
for KUKA System Software (KSS) Release 5.2, 5.3, 5.4
Issued: 14 Dec 2005
Version: 03
ArcTechAnalog_Bed_R1.0 02.05.03 en
1 of 76
e Copyright
2005
KUKA Roboter GmbH

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.
2 of 76
Contents
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
Brief description of the commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
2.1
Additional safety instructions for KUKA.ArcTech Analog . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
2.2
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
2.3
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
2.4
2.4.1
2.4.2
Symbols and icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
Installing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
3.1
Installation / uninstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
3.2
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
The graphical user interface - KUKA Control Panel (KCP) . . . . . . . . . .
15
4.1
4.1.1
Function of the menu keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configure menu, Status keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
4.2
4.2.1
4.2.2
4.2.3
Key functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function of the Technology menu key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function of the softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function of the left--hand status keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
16
17
Programming and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
5.1
Basic settings; peripheral equipment adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
5.2
Program run mode for welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
5.3
Creating a program for ArcTech Analog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
5.4
Entering commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
5.5
Variables in input boxes of the inline forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
5.6
5.6.1
5.6.2
5.6.3
Start welding -- ARC_ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming the welding start ARC_ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
22
22
23
5.7
5.7.1
5.7.2
5.7.3
Welding several seam sections -- ARC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of motion for the ARC SWITCH command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming ARC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
29
29
30
5.8
Welding and ending a seam (ARC OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
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5.8.1
5.8.2
5.8.3
5.8.3.1
5.8.4
5.8.5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of motion for the ARC OFF command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inline form and parameter lists for ARC OFF, weld and end parameters . . . . . . . . . . . . . .
Inline form with TRACK function when sensor is active (KUKA.ArcSense) . . . . . . . . . . . .
Parameter lists for weld parameters (W) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
35
36
38
40
41
5.9
5.9.1
Mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weave frequency, weave length, path velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
45
5.10
Thermal weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
5.11
Combined mechanical and thermal weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
5.12
Ramp function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
5.13
5.13.1
5.13.2
Extended weld parameter lists for special applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional weld parameter lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter list for the end parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
53
54
Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
6.1
Starting welding of seam 1 -- ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
6.2
Ending welding of seam 1 -- ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
6.3
Moving to seam 2 (PTP) and starting welding -- ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
6.4
Welding seam 2 (up to P8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
Altering existing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
7.1
Altering command lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
7.2
Deleting command lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
Adding commands to an existing program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of the alteration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Altering the Motion command (to P3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting the welding start for the new seam -- ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting the first section of the new seam -- ARC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting the second section of the new seam -- ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting a point in space -- Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
68
68
68
68
69
69
Online optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
8.1
Function overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
8.2.7
Modification of the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Modifying the velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity modification limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deselecting the online optimizing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block selection response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modifying the weld voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modifying the wire feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modifying the weave parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
72
73
73
73
73
74
74
8.3
Interrupt response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
8.4
System response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
4 of 76
Override for correction motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
9.1
Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
9.2
Correction motion override and online optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
10
Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
5 of 76
6 of 76
Introduction
Introduction
1.1
Functions
The KUKA.ArcTech Analog technology package allows the creation of robot--controlled arc
welding applications for weld power sources with an analog reference voltage. The
development of welding robots that are easy and safe to use has been made possible by the
universal adaptation of the user interface and other interfaces to a wide range of
analog--controlled welding equipment, and by the user--friendly handling of the
KUKA.ArcTech Analog technology package.
Fig. 1 shows the basic structure of the KUKA.ArcTech Analog commands. You can see how
the motion and weld commands and the start and end parameters are assigned to the
individual sections of a seam.
ARC INI
ARC SWITCH
ARC ON
8
6
P1
P2
1
1
Seam section 1
Seam section 2
Welding torch
Initialization
Arc start parameters
Arc weld parameters
Arc end parameters
Motion parameters
ARC OFF
P3
Fig. 1 Structure of KUKA.ArcTech Analog commands
7 of 76
1.2
Brief description of the commands

An initialization command and three program commands, which are used to control the
welding equipment, are basically available for gas metal--arc welding with an analog
reference voltage. These commands are:
G INI
This initialization command is automatically entered at the beginning of the skeleton program
when a new program is created. This sets the basic weld parameters for the robot and the
application program and initializes the welding and motion commands and approximate
positioning. The parameters can only be changed by the Expert user group.
G ARC ON
The ARC ON command contains the parameters for moving the welding torch (type of
motion, speed, etc.) from the home position to the start point of the seam, and all the ignition
parameters. ARC ON ends after ignition has been successfully completed.
G ARC SWITCH
The ARC SWITCH command is used where the seam is divided into several sections. It
contains the motion and weld parameters (including mechanical and thermal weaving) for
the current section of the seam.
The set weld parameters are used as a default setting for all of the following ARC SWITCH
commands.
A command from the Motion group is used for moving the welding torch, e.g. from the end
of a seam (ARC OFF) to the home position of a following ARC ON command, and for
reorienting the welding torch.
G ARC OFF
The ARC OFF weld command contains the motion and weld parameters (including
mechanical and thermal weaving) and the end parameters for the seam, or for the last
section of the seam if it is divided into several sections.
ARC OFF ends the welding process by filling the crater and burning back excess wire, so
that the correct free wire length and form are ensured for the ignition process at the start of
the next seam.
Detailed information on motion programming can be found in the [Operating Handbook],
in the chapter Motion Programming.
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Introduction (continued)
This documentation has been created for the User user group. It contains the description
of the graphical user interface of the KUKA Control Panel and illustrates the operator actions
necessary for creating, testing, correcting, altering and optimizing programs of the
KUKA.ArcTech Analog technology. Explanatory information on the technology commands
and the associated parameters is also included.
The functions that are specific to KUKA.ArcTech Analog, the operator control elements, the
menus, and the various inline forms of the KUKA Control Panel are described in Chapter 4 Graphical user interface of the KUKA Control Panel.
Chapter 5 - Programming and operation -- contains the description of the individual
KUKA.ArcTech Analog commands together with various tables and information on
programming. The command--specific overviews showing the parameter lists assigned to the
inline forms, together with a brief description of the parameters and of the frequently required
operator control elements, can be useful, especially for less experienced users.
By using the simple examples given in both Chapter 6 - Program example - and
Chapter 7 -- Altering existing programs --, where the individual steps required for creating
and altering programs are illustrated, even less experienced users can quickly familiarize
themselves with programming.
Chapter 8 -- Online optimizing -- contains a description of how to carry out online optimizing.
As a user, you should have adequate knowledge regarding the creation of motion
programs. More detailed information on this can be found in the [Operating Handbook], in
the chapter Motion Programming.
The documentation [KUKA.ArcTech.Analog -- Configuration] contains detailed information
on programming and setting parameters for the Expert user group.
The meaning of the symbols, icons, and particular font conventions is also explained in the
[Operating Handbook], in the chapter About this Documentation.
It is assumed that the robot system has been prepared for production operation and that
the technology package has been loaded. Information on this can be found in the
[Operating Handbook] in the chapter Start--up.
9 of 76
1.3
Basic settings
The following is an overview of the important software settings for the configuration of the
KUKA.CR.ArcTech Analog technology package.
Unless otherwise stated, settings and changes to the variable values only become active
after the system is restarted. The following procedure is carried out:
G
When configuration is complete, save the data on the hard disk.
Menu function: File Save all to floppy
G
Once the data have been saved, shut the system down.
G
Restart the system.
Configurable options
The following configurable options are available:
Variable
A_ACT_AN_MAX
A50_OPTION
Value
1--8
1
8
Default: 2
#DISABLED
#ACTIVE
Default:
#DISABLED
Meaning
Number of parameter list elements
Display of the inline forms for through-the--arc weave sensor (KUKA.ArcSense)
Note:
Only available if the ArcTech Analog
(Thick with TAST Sensor)
Sensor) option was
selected when installing this technology
package.
A_RAMP_OPTION
TRUE
FALSE
Default:
FALSE
Additional parameter list element, displayed

with configurable length in [mm].
A_TH_WEAVE_OPT
TRUE
FALSE
S
Default:
FALSE
Appearance of the parameter list page

with
t settings
sett gs for
o thermal
t e a weaving.
ea g
#ACT_PAR
#REDUCE
Default:
#ACT_PAR
Appearance of the parameter list with

separate
burnback parameters
for each
p
p
weld
ld data
d t set.
t
A_BB_MODE
For setting options, see Section 5.6
10 of 76
Safety
Safety
WARNING!
Failure to observe these safety instructions could result in injury or a fatal accident
and/or damage to the robot system or other property!
2.1
2.2
All pertinent safety regulations as well as the booklet [Safety and Installation
Instructions] are to be observed when working on the system.
The KUKA safety chapter [KRC Safety, General] is supplied with the robot system and
must be read and understood before commencing work.
The safety instructions in the KR C2 Operating Handbook must be observed.
Additional safety instructions for KUKA.ArcTech Analog

G
Installation, exchange, and service work on this technology package or individual

components thereof may only be performed by qualified personnel specially trained for
this purpose and acquainted with the risks involved.
Follow the safety instructions provided by the manufacturer of the welding system used.
Liability
The KUKA.ArcTech Analog technology package has been designed, built, and
programmed using state--of--the--art technology and in accordance with the recognized
safety rules. Nevertheless, improper installation of this unit or its employment for a purpose
other than the intended one may constitute a risk to life and limb of operating personnel or
of third parties, or cause damage to or failure of the control cabinet, resulting in damage to
or failure of the entire robot system and other material property.
KUKA.ArcTech Analog may only be used in technically perfect condition in accordance with
its designated use and only by safety--conscious persons who are fully aware of the risks
involved in its operation. Connection and use must be carried out in compliance with this
documentation.
2.3
Designated use
KUKA.ArcTech Analog is a technology package for arc welding with power sources with
an analog reference voltage, for operation with a KUKA robot controller.
11 of 76
2.4
Symbols and icons

The safety symbols and icons described in the following are used in this documentation:
2.4.1
Safety symbols
Text passages indicated by these safety symbols are important for safety and must be observed.
WARNING!
Exact compliance with these safety warnings is necessary for the prevention of
personal injury.
CAUTION!
Exact compliance with these safety warnings is necessary for the prevention of
damage to property.
2.4.2
Icons
Info
Indicates passages which are of particular significance or are useful for greater understanding.
See also
Indicates sections or chapters containing further information and explanations.
NOTE
Indicates sections with additional information on a particular subject and highlights special
features.
12 of 76
Installing the software
Installing the software
3.1
Installation / uninstallation
From KSS Release 5 onwards, technology packages are offered exclusively as add--on
software modules. These are available on CD--ROM.
Installing, uninstalling, reinstalling and updating technology packages is described in detail
in the documentation [Installation/Uninstallation/Update of Tech Packages].
3.2
Setup
When performing the setup, a menu appears on the screen for selecting the KUKA.ArcTech
Analog option to be installed.
The following three options are available for selection:

G
ArcTech Analog (Thin)
ArcTech Analog (Thick)
ArcTech Analog (Thick with TAST Sensor)
The KUKA.ArcSense through--the--arc seam tracking sensor, which is only available if

the ArcTech Analog (Thick with TAST Sensor) option has been selected during program
installation, is described in the documentation [KUKA.ArcSense].
13 of 76
14 of 76
The graphical user interface -- KUKA Control Panel (KCP)
The graphical user interface - KUKA Control Panel (KCP)

This section discusses the expansion of the graphical user interface of the KUKA Control
Panel (KCP) for KUKA.ArchTech Analog.
A basic description of the user interface (HMI) and how to operate it can be found in the
[Operating Handbook -- KUKA System Software], in the chapter Operator Control.
Creating, selecting and altering a program is described in the chapter Program creation
in the [Operating Handbook].
4.1
Function of the menu keys
4.1.1
Configure menu, Status keys

The menu function Configure ! Status keys ! ArcTech Analog activates the program-specific functions for the KUKA.ArcTech Analog option in the status key bar on the left-hand side.
Fig. 2 Activating status keys for KUKA.ArcTech Analog
For detailed information on the functions of the KUKA.ArcTech Analog status keys,
see Section 4.2.3.
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4.2
Key functions
A series of softkeys are available for operation and entering commands, with a distinction
being made between menu keys, softkeys, and status keys. The following describes the
functions of the program--specific keys of KUKA.ArcTech Analog.
4.2.1
Function of the Technology menu key

The menu function Technology ! ArcTech Analog causes a selection menu to appear:
The weld commands ARC ON, ARC SWITCH, and ARC OFF are available for selection.
The following types of motion are available for selection:
G PTP, LIN, or CIRC for the weld command ARC ON,
G LIN or CIRC for the weld commands ARC SWITCH and ARC OFF.
In the following example, ARC ON, PTP has been selected.
When the Enter key is pressed, an inline form is opened in the program window:
4.2.2
Function of the softkeys

The assignment of the softkey bar changes after a weld command is selected:
The function of these softkeys is as follows:

Cmd Abort
It is possible to abort programming at any time by means of the Cmd Abort softkey. In this
case, none of the data are saved and the inline form is closed. The ESC key has the same
function.
LIN/CIRC
This softkey displays the motion types that have not been selected; in this example, PTP
motion has been selected. Pressing this softkey changes the type of motion to the one which
appears first (LIN in this example). The changed motion type is automatically accepted and
the inline form and softkey bar are updated.
ARC SWI
ARC OFF
It is possible to change the selected weld command (ARC ON in this case) by means of
the softkeys ARC SWI and ARC OFF. The inline form that is currently open is closed and
a form corresponding to the new command is opened. The softkey bar is updated at the same
time.
Touch Up
The current robot coordinates are saved by pressing the Touch Up softkey.
Cmd OK
The Cmd OK softkey saves the data and closes the form. The newly created command line
appears in the program list and the edit cursor is moved to that line. The Enter key has the
same function.
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4.2.3
The graphical user interface -- KUKA Control Panel (KCP) (continued)
Function of the left--hand status keys

Provided that the ArcTech Analog status key bar has been selected in the Configure
menu, four control keys specific to ArcTech Analog for manual wire feed, manually
controlled welding, and DRY (dry run) are available in the left--hand status key bar.
Manual control of the wire feed
These two status keys allow wire feed to be controlled manually. The following options are
available:
Status key +: wire is fed.
Status key --: wire is retracted.
These two functions cannot be used during an active welding process.
The functions of these status keys are only available after they have been configured in
$CONFIG.DAT and the system has been rebooted.
Controlling welding (HOT/COLD) and dry run (DRY)

The two status keys HOT/COLD and DRY have a toggle function with reciprocal lockout.
It is not possible to switch directly from HOT (welding on) to DRY and vice versa.
The screenshot on the left shows the status Welding and DRY switched off, which can be
identified by the crossed--out welding torch icons. In this position, only the motions of a
welding program can be executed; actual welding does not take place. The wire feed and
the shielding gas are switched off.
The HOT/COLD status key always has to be switched on for welding (HOT).
This status key is also used to switch manually between HOT (welding) and COLD (robot
motion only): so--called On/Off switching on the fly.
The DRY status key is locked and deactivated when the HOT status key is switched on.
In Automatic External mode, you first need to switch to HOT as otherwise the functions
of the status keys will not be available.
With the setting A_HOT_SELECT = #ACTIVE, ignition will occur when a

block containing ARC_SWI is selected.
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When the DRY status key is activated, the robot moves at a higher velocity (in accordance
with the default setting DRY_RUN_Vel Default = 0.15m/s in $CONFIG.DAT). The welding
process, the wire feed, and the shielding gas are then switched off and any mechanical
weaving that has been programmed is not executed.
NOTE:
This speed may not be increased, for reasons of safety!
When the computer starts up, (hot) welding is always deactivated, as indicated by the
crossed--out welding torch icon on the left--hand status key bar. In order to be able to weld,
this status key has to be switched to the HOT position corresponding to the symbol shown
on the left.
The functions of both the Jog mode status key at top left (manual movement of the robot
using the Space Mouse or the right--hand status keys) and the Program run mode status
key beneath it are described in the [Operating Handbook], in the chapter Controller, KCP
Display.
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Programming and operation
Programming and operation

This section describes how to create new programs and how to program welding and motion
commands. It also contains information on everything that has to be taken into account when
setting individual parameters.
Only alter variables if you have adequate knowledge of their function, and of the
possible consequences!
5.1
Basic settings; peripheral equipment adaptation

Detailed information and instructions on this can be found in the documentation
[KUKA.ArcTech Analog -- Configuration].
The default variables may have to be changed in order to adapt them to the periphery (weld
controller, welding mode, number of analog channels, burnback mode). A brief overview follows.
Burnback mode (A_BB_MODE)
It is possible to select between various burnback modes by means of the A_BB_MODE
variable.
The factory setting for A_BB_MODE is #ACT_PAR.
Corresponding entry using the menu function Monitor -- Variable -- Single:
Variable
Value
Possible values
A_BB_MODE
#ACT_PAR
Default setting
#REDUCE
The wire feed is set to zero and the voltage is

reduced.
(A_REDUCE= 0.2 20% of the current
value of channel 1)
A_BB_MODE
5.2
Program run mode for welding

Welding is only possible in the program run mode GO. With program run modes MSTEP
and ISTEP, the program would not be able to run properly.
When the controller is started up, it will be restored to the status it was in when the computer
was last shut down. In order to be able to weld, this status key has to be switched to the HOT
position corresponding to the symbol shown on the left.
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5.3
Creating a program for ArcTech Analog

To create a welding program for KUKA.ArcTech Analog, you first need to create a robot
program.
When the New softkey is pressed, the screen will display a selection of templates, as shown
in Fig. 3.
Fig. 3 Creating a welding program -- selecting the ArcTech template

Select the ArcTech template and enter the required data.
You always need to select the ArcTech template when creating a welding program.
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5.4
Programming and operation (continued)
Entering commands
For a number of commands, the KUKA Control Panel provides several methods of entering
them. For example, the command for opening an inline form for ARC ON can be entered
by means of the Technology menu key.
After pressing the Technology menu key, you can select options from the menus by means
of the arrow keys. See also Section 4.2.1 of this documentation.
5.5
Variables in input boxes of the inline forms
The inline forms contain a series of input boxes, whose designations are freely selectable.
This applies to the following boxes:
P1
Designation of the end point
PDAT1, CPDAT1
Designation of the motion parameters data set
PS or MM
Designation of the particular weld mode
Designation of the start parameters data set
W1
Designation of the weld parameters data set
Designation of the end parameters data set
Seam1
Comment (max. 24 characters)
The following must always be observed:

-- The designation can consist of letters and numbers. Special characters cannot be
used, except for the underscore _.
-- The first character of a designation always has to be a letter.
-- The designation for the boxes mentioned above may consist of no more than 24
characters.
-- The designation is taken over unchanged as a pure character string into all of the
subsequent program lines.
-- If the last character is a number, the value of this number is automatically incremented
(n +1) in the subsequent commands, e.g. W1, W2 ... Wn or SEAM_FRONT1,
SEAM_FRONT2 ...SEAM_FRONT99.
Please remember that the number of characters increases by 1 when going from 9 to 10.
Should this lead to the designation exceeding 24 characters, which is not permitted, the
remainder of the comment is cut.
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5.6
Start welding -- ARC_ON
5.6.1
General
The ARC ON command contains the parameters for moving the welding torch (motion type,
velocity, etc.) from the home position to the start point of the seam, and all the start and ignition
parameters, including options that have been selected (e.g. aluminum ignition process).
While the ARC ON program phase is being executed, the system constantly checks
whether the ignition conditions are satisfied. ARC ON ends after ignition has been
successfully completed.
5.6.2
Types of motion
The movement from the home position to the start point of the seam can be executed as a
PTP, LIN, or CIRC motion.
The path cannot be predicted exactly for PTP motions. The motion characteristics of
the robot near obstacles should therefore be checked in a test run.
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5.6.3
Programming the welding start ARC_ON

When you select Technology ! ArcTech Analog! ARC ON ! PTP, the inline form
set out in Fig. 4 will appear.
Seam1
Frames
Tool coordinate
system (1...16 or
NULLFRAME)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP
Start parameters
Start Parameter
Pre Flow Time
Start Time
Start time
(0 to 1.5 sec)
Voltage
Start voltage
(13 to 39 V)
Wire Feed
Wire feed
(0 to 20 m/min)
External TCP
True or False
Motion
Start Parameter
Acceleration
(1 to 100 %)
Gas preflow time

(0 to 1.5 sec)
Only when number

of analog channels
>2
Reserved for an
additional analog
channel
Fig. 4 Inline form and parameter lists for the command ARC ON, PTP
In the parameter list Frames, note that external axes can also be set under Base.
The entry EX_AX_DATA [ ] only appears in the window, however, if an external axis is
correspondingly configured in the machine data.
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Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
Box
Function
Range of values, comments
PTP
Type of motion
Change using bottom right status

key, softkey bar, or keypad.
P1

(teach using Touch Up softkey)
Freely selectable (see Section 5.5).

The designation Pn can be
changed using the keypad or the
bottom right status key.
Vel =100%
Path velocity
1 to 100% of the maximum value

(default: 100%).
Change by entering a value by
means of the numeric keypad or
the bottom right status key.
PDAT1
Designation of the motion

parameters
PS
Welding process
PS = Pulse
(Mode 1)
MM = MIGMAG (Mode 2)
Designation of the start

parameters
Freely selectable (see Section 5.5)
Seam1
Comment
Recommendation for the motion parameters:

Entry of PDAT without a number is recommended; with this type of entry, the data sets are
not incremented and regenerated. This has the advantage that fewer data are used.
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When you select Technology ! ArcTech Analog! ARC ON ! LIN, the inline form set
out in Fig. 5 will appear.
Seam1
Frames
Tool coordinate
system (1...16 or
NULLFRAME)
External TCP
Start Parameter
Start parameters
Pre Flow Time
Gas preflow time

(0 to 1.5 sec)
Base coordinate
system (1...16 or
NULLFRAME)
Start Time
Start time
(0 to 1.5 sec)
External TCP
True or False
Voltage
Start voltage
(13 to 39 V)
Wire Feed
Wire feed rate

(0 to 20 m/min)
Motion
Start Parameter
Acceleration
(1 to 100 %)
Only when number

of analog channels
>2
Reserved for an
additional analog
channel
Fig. 5 Inline form and parameter lists for the command ARC ON, LIN
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Box
Function
LIN
Type of motion

P1


The designation Pn can be
changed using the keypad or the
bottom right status key.
Vel =1.25m/s
Path velocity
0.001 to 2 meters per second

(default setting: 2 m/s).
Change by entering a value by
means of the numeric keypad or
the bottom right status key.
CPDAT1

parameters
PS
Welding process
PS = Pulse
(Mode 1)
S1
Designation of the start

parameters
Seam 1
Comment

Entry of CPDAT without a number is recommended; with this type of entry, the data sets
are not incremented and regenerated. This has the advantage that fewer data are used.
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When you select Technology ! ArcTech Analog! ARC ON ! CIRC, the inline form
Seam1
Frames
External TCP
Start Parameter
Start parameters
Tool coordinate
system (1...16 or
NULLFRAME)
Pre Flow Time
Base coordinate
system (1...16 or
NULLFRAME)
Start Time
External TCP
True or False
Voltage
Start voltage
(13 to 39 V)
Wire Feed
Wire feed rate

(0 to 20 m/min)
Gas preflow time

(0 to 1.5 sec)
Start time
(0 to 1.5 sec)
Motion
Start Parameter
Acceleration
(1 to 100 %)
Only when number

of analog channels
>2
Reserved for an
additional analog
channel
Fig. 6 Inline form and parameter lists for the command ARC ON, CIRC
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Box
Function
CIRC
Type of motion

P1
Designation of the auxiliary point

(teach using Teach Aux softkey)

Change the designation by using
the keypad or the bottom right
status key.
P2

(teach using Teach End softkey)

status key.
For the remaining parameters, see the description for the command ARC ON ! LIN
in this section.
Parameter list for the start parameters

The values for the start time, the gas preflow time, the ignition voltage, and the wire feed rate
at the start are defined in the Start parameters parameter list. This parameter list offers the
following ranges of values:
Start parameters, page 1
Start Parameter
Pre Flow Time
Gas preflow time

0 to 1.5 seconds
Start Time
Start time
(delay of weld start)
0 to 1.5 seconds
Voltage
Start voltage
*)
Wire Feed
9.5
Wire feed rate at start

20
9.5
*)
*) Value ranges and units vary depending on configuration

Fig. 7 Inline form for start parameters, page 1
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Start Parameter
Start parameters, page 2

Only available if the number of analog
channels >2 (e.g. A_ACT_AN_MAX=3)
Reserved for parameters of an additional
analog channel
Fig. 8 Inline form for start parameters, page 2

For further information, refer to Section 1.3 in this documentation.
5.7
Welding several seam sections -- ARC SWITCH
5.7.1
General
The ARC SWITCH command is used between the commands ARC ON and ARC OFF
when the seam is divided into several sections with different motion and/or weld parameters.
It contains the motion and weld parameters for the current section of the seam, including the
parameters for mechanical and thermal weaving. The set weld parameters are used as a
default setting for all of the following ARC SWITCH commands.
5.7.2
Types of motion for the ARC SWITCH command

Two types of motion can be selected for the ARC SWITCH command:
LIN -- linear motion -- and CIRC -- motion along a circular path. While the robot is always
exactly positioned in the case of ARC ON and ARC OFF, approximate positioning is
possible with ARC SWITCH.
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5.7.3
Programming ARC SWITCH

When you select Technology ! ArcTech Analog! ARC SWITCH ! LIN, the inline
form set out in Fig. 9 will appear.
Frames
Tool coordinate
system (1...16 or
NULLFRAME)
Motion
Acceleration
(1 to 100%)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP True
or False
Fig. 9 Inline form and parameter lists for the command ARC SWITCH, LIN
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Box
Function
LIN
Type of motion

P2


status key.
CONT
Approximate positioning
No entry = without approximate

positioning CONT = with
approximate positioning
The entry CONT should be set
permanently to prevent excessive
weld pool formation.
Default: approximation distance =
5.0 mm ($config.dat:
A_AP_DIS_TCH=5.0)
CPDAT1

parameters

31 of 76
When you select Technology ! ArcTech Analog! ARC SWITCH ! CIRC, the inline
form set out in Fig. 10 will appear.
Frames
Tool coordinate
system (1...16 or
NULLFRAME)
Motion
Acceleration
(1 to 100%)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP True
or False
Fig. 10 Inline form and parameter lists for the command ARC SWITCH, CIRC
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Box
Function
CIRC
Type of motion

P2


status key.
P3


status key.
CONT
Approximate positioning
No entry = without approximate

positioning
CONT = with approximate
positioning
The entry CONT should be set
permanently to prevent excessive
weld pool formation.
Default:
approximation distance = 5.0 mm
($config.dat: A_AP_DIS_TCH=5.0)
CPDAT1

parameters

33 of 76
The part of the inline form and the parameter lists for the weld parameters of the ARC
SWITCH command are set out in Fig. 11.
Weld parameters 1) Only if A_TH_WEAVE_OPT = TRUE.
Primary Weld
Weld velocity
Travel Speed
Thermal
weaving 1)
Thermal Weaving
(0 to 2 m/min)
Weave Type
Voltage
Volts
Weave type
Weld voltage
(13 to 39 V)
Voltage
Weld voltage
(13 to 39 V)
Wire Feed
Wire feed rate

(0 to 20 m/min)
Wire feed
(0 to 20 m/min)
Wire Feed
20
Burnback time *)
(0 to 1.5 sec)
Burnback Time
Thermal weave
length
(1.5 to 12 mm)
Thermal Weave Length
Mechanical
weaving
Mechanical Weaving
2) Only if A_RAMP_OPTION = TRUE.
Weave Type
Figure
Weave type
Ramp function
4/5
Weave Length
Weave length
(1.5 to 12 mm)
Weave Amplitude (zero to peak)
Ramp length
Ramp length (0
to 25 mm)
Weave amplitude
(1 to 15 mm)
Weave Angle
Degrees
Weave angle
(--180 to +180
degrees)
*)
Only visible if the variable HIDE_BB_TIME=FALSE is set in A10.DAT
1) 2) May only be activated if the variable A50_OPTION=#Disabled
Fig. 11 Inline form and parameter lists for ARC SWITCH, weld parameters
34 of 76
Box
Function
PS/MM
Welding process
PS = Pulse
(Mode 1)
W1
Designation of the weld

parameters.
Freely selectable (see Section

5.5).
Information on the Weld parameters parameter list and details regarding mechanical
and thermal weaving can be found in Sections 5.9 and 5.10.
5.8
Welding and ending a seam (ARC OFF)
5.8.1
General
The ARC OFF weld command contains the motion and weld parameters for the following:
-- The seam from where welding has been successfully started (ARC ON) up to the end
of the seam, provided that the same motion and weld parameters are used for the
entire seam,
-- The last section of the seam from the ARC SWITCH command up to the end of the
seam if the seam is divided into several sections with different motion and/or weld
parameters, and
The end parameters for crater filling, the gas postflow time, and burnback of excess wire.
5.8.2
Types of motion for the ARC OFF command

Two types of motion can be selected for the ARC OFF command:
LIN -- linear motion -- and CIRC -- motion along a circular path. Approximate positioning
is not possible; motions are exactly positioned to each point.
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5.8.3
Programming ARC OFF

When you select Technology ! ArcTech Analog! ARC OFF ! LIN, the inline form
Frames
Motion
Tool coordinate
system (1...16 or
NULLFRAME)
Acceleration
(1 to 100%)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP True
or False
Fig. 12 Inline form and parameter lists for the command ARC OFF, LIN
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Box
Function
LIN
Type of motion

P2


status key.
CPDAT1

parameters

When you select Technology ! ArcTech Analog! ARC OFF ! CIRC, the inline form
After selecting the command ARC OFF -- CIRC, the inline form shown below is opened:
Frames
Motion
Tool coordinate
system (1...16 or
NULLFRAME)
Acceleration
(1 to 100%)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP True
or False
Fig. 13 Inline form and parameter lists for the command ARC OFF, CIRC
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Box
Function
CIRC
Type of motion

P2


status key.
P3


status key.
CPDAT1

parameters

5.8.3.1
Inline form and parameter lists for ARC OFF, weld and end parameters
The part of the inline form and the parameter lists for the weld and end parameters of the
ARC OFF command are set out in Fig. 14.
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Primary Weld
Weld parameters
Travel Speed
Weld velocity
Only if A_RAMP_OPTION = TRUE.

Ramp function
4/5
Ramp function 2)
(0 to 2 m/min)
Weld voltage
(13 to 39 V)
Voltage
Volts
Wire Feed
10
Burnback Time
Mechanical Weaving
Weave Type
Weave Length
20
Ramp length
(0 to 25 mm)
Wire feed rate

(0 to 20 m/min)
Burnback time*
(0 to 1.5 sec)
Mechanical
weaving
Weave type
Seam--specific
burnback data
End Set
Crater Time
Crater time
(0 to 1.5 sec)
Weave length
(1.5 to 12 mm)
Voltage (Crater Filling)
Weave amplitude
Crater voltage
(13 to 39 V)
Weave amplitude
(1 to 15 mm)
Wire Feed (Crater Filling)
Weave Angle
Thermal Weaving
Weave angle
(--180 to +180
degrees)
10
Burnback time
Thermal
weaving 1)
20
Wire feed rate

(0 to 20 m/min)
Burnback time*
(0 to 1.5 sec)
Weave Type
Weave type
Voltage
Weld voltage
(0 to 39 V)
End Set
Post Flow Time
Seam--specific
burnback data
Gas postflow time
(0 to 1.5 sec)
Wire Feed
Wire feed rate

(0 to 20 m/min)
Thermal weave length
Thermal weave
length
(1.5 to 12 mm)
1) Only if A_TH_WEAVE_OPT = TRUE.
*)
Only visible if the variable HIDE_BB_TIME=FALSE is set in A10.DAT
1) 2) May only be activated if the variable A50_OPTION=#Disabled
Fig. 14 Inline form and parameter lists for ARC OFF, weld and end parameters
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5.8.4
Box
Function
PS/MM
Welding process
PS = Pulse
(Mode 1)
W1
Designation of the weld

parameters.
Designation of the end

parameters.
Seam 1
Comment
Inline form with TRACK function when sensor is active (KUKA.ArcSense)

The inline form illustrated in Fig. 15 also contains the selection box TRACK. The TRACK
function is only available if the KUKA.ArcSense sensor has been installed and activated
(A50_OPTION=#ACTIVE).
Once TRACK has been selected, another box, T, is added.
If box T has the focus, the Tracking Conditions parameter list is opened in the status
window offering the option of adjusting the settings for the through--the--arc sensor.
The Track function is available with

ARC SWITCH and ARC OFF.
Tracking Conditions
Fig. 15 TRACK function
For detailed information on the functions and configuration of the KUKA.ArcSense through-the--arc seam tracking sensor, see the [KUKA.ArcSense] documentation.
40 of 76
5.8.5
Parameter lists for weld parameters (W)

The Primary Weld parameter list consists of four pages. The parameters entered here are
saved in the W n data set.
Primary Weld
This page (see Fig. 16) contains the parameters for the weld voltage and the wire feed rate. If
the Thermal weaving option is selected (see also Section 5.10), the values for the weld voltage
and the wire feed rate that are set in this parameter list are the maximum values for each.
The maximum and minimum values are dependent on the welding rectifier and must be
adapted accordingly in the registry.
More detailed information about making modifications in the registry can be found in the
documentation [KUKA.ArcTech Analog -- Configuration].
Only carry out modifications in the registry if you know exactly what you are doing!
Otherwise, contact KUKA Roboter GmbH.
This parameter list covers the following ranges of values:

Primary Weld
Primary Weld
Travel Speed
Weld velocity
0 to 2 meters per minute
Voltage
Weld voltage
*)
Wire Feed
Wire feed rate

*)
Burnback Time
Burnback time
0 to 1.5 seconds

Fig. 16 Primary Weld parameter list
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5.9
Mechanical weaving
Mechanical weaving is used, for example, to compensate for component tolerances or to
bridge gaps in a seam. The torch moves across the seam in this instance and the weave
oscillation is thus superposed on the seam motion. It is also possible to rotate the torch in
relation to the component plane.
Mechanical weaving
Mechanical Weaving
Weave Type
Weave type
Without weaving (No Weave),
10 patterns as per table,
2 freely definable patterns
Figure
Weave Length
Weave length*)
1.5 to 12 mm
Weave amplitude
Weave amplitude
Half of the total weave width, from peak to 0.
1 to 15 mm
Weave Angle
Weave angle
Degrees
--180 to +180 degrees

*) Information about applications in which
thermal and mechanical weaving are combined
can be found in Section 5.11.
Fig. 17 Mechanical weaving parameter list
In the case of mechanical weaving, the effective weld velocity (travel speed) is greater than
the path velocity, due to the weave amplitude and weave length.
Weave seam (triangle)
Weave amplitude *)
Length of the path
Welding torch
Direction of welding
Effective length
of the seam
Weave width
Weave length
*) Weave amplitude = half the weave width

Fig. 18 Mechanical weaving
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Fig. 19 and Fig. 20 show the weave patterns available. Trapezoidal, spiral and figure--eight
weave patterns result in a non--uniform effective weld velocity. This can vary during one
period between the set path velocity and a multiple of it, depending on the relation of the
lateral deflection (amplitude) to the weave length.
s
Weave amplitude
Weave length
s
No weave
Triangle
Double triangle
Trapezoid
Double trapezoid
Unsym. trapezoid
Spiral
Double 8
Fig. 19 Weave patterns for mechanical weaving (1 of 2)
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Edge weave
bottom
Weave length
s
z
s
y
Edge weave top
Weave length
s
s
Fig. 20 Weave patterns for mechanical weaving (2 of 2)

With the weave patterns Edge weave bottom und Edge weave top shown in Fig. 20, the
weave angle changes within one weave length.
With the Edge weave bottom pattern, the torch is deflected laterally (direction y) in the first
half according to the weave amplitude defined [s] and vertically in the second half
(direction z). With the Edge weave top pattern, the deflection is vertical (z) in the first half
and lateral (y) in the second half.
The lateral deflection (amplitude), the weave length (the length over which a pattern is
executed) and the angle of the torch to the welding plane can be set for each weave pattern.
In the Expert user group, two further weave patterns can be defined with the designations
User def. pattern 1 and User def. pattern 2 in the Arc_weave.src file, and existing
patterns can be modified. Detailed information on this can be found in the documentation
In order to generate a circular or spiral weld pattern, the amplitude must be half the weave
length.
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5.9.1
Weave frequency, weave length, path velocity

Of significance for correct functioning of the robot is the weave frequency, which results
from the programmed weld velocity (travel speed) and the weave length. The following
relationships exist between these parameters:
Weave frequency f
Weave length s
Weld velocity v
Path velocity [m/min] 1000

Weave length [mm] 60
[Hz]
Path velocity [m/min] 1000

Weave frequency [Hz] 60
[mm]
Weave frequency [Hz] Weave length [mm] 60 [m/min]

1000
Fig. 21 Weave frequency -- Weave length -- Weld velocity

These relationships are depicted graphically in the nomogram shown in Fig. 22.
Weave length s
[mm]
0.3 0.5
12
0.75 1.0
1.25
1.5
Weave frequency f
[Hz]
2.5
3.0
2.0
11
10
3.5
4.0
9
8
7
5.0
6.5
5
4
3
2
1.5
0
.1
.2
.3
.4
0
0.5
Weld velocity v m/min
.6
.7
.8
.9
.1
.2
.3
.4
1.0
For weave frequencies > 3
Hz, see explanation in text.
.6
.7
.8
.9
1.5
2.0
Non--permissible range
Fig. 22 Relationship between weave frequency -- weave length -- weld velocity
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The maximum weave frequency for mechanical weaving is influenced by several factors
depending on the robot type concerned, for example by the resonant frequency of the
robot/tool mechanical unit. Weave frequencies of up to 3 Hz (corresponding, for example,
to a weave length of 3.33 mm at a travel speed of 0.6 m/min) are possible without causing
problems according to previous experience.
With higher weave frequencies, undesirable effects are liable to result under certain
circumstances (depending on the tool design and/or tool orientation). With weave
frequencies > 3 Hz, the motion characteristics of the robot should therefore be individually
tested in each case.
Further information on mechanical weaving can be found in the documentation
Rotation of the weave plane

In certain applications, it may be necessary to rotate the weave plane. The range of possible
settings is --180 to +180 degrees.
Mechanical Weaving
Weave Angle
Degrees
Weave amplitude
Torch plane
Torch plane
Torch
Torch
Weave plane
Weave plane
Component
plane
Weave angle degrees
Weave angle 0 degrees
Fig. 23 Rotation of the weave plane
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If the sensor (KUKA.ArcSense) is being used, it is not possible to change the angle of the
weave plane; the angle is permanently 0 degrees!
In order to achieve the correct distribution of heat, the torch must then be positioned at an
angle.
In the event of a TRACK command, the weave angle is permanently set to 0 degrees.
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5.10
Thermal weaving
The Thermal weaving option may not be activated when the KUKA.ArcSense sensor option
is active (A50_OPTION=#ACTIVE).
In conventional welding processes, the values for the weld voltage and the wire feed rate
remain constant. Thermal weaving is an option for use with certain applications (e.g. for
reducing the welding distortion).
It involves periodic alteration of the weld voltage and the wire feed rate. The result is a seam
with weld metal that varies periodically in relation to these changes.
The robot--specific Thermal weaving mode has nothing in common with the Pulsing option
offered by welding equipment.
A precondition for displaying the Thermal weaving parameter list is that the variable
A_TH_WEAVE_OPT is set to the value TRUE.
Variable
A TH WEAVE OPT
A_TH_WEAVE_OPT
Value
Characteristics
TRUE
Flag for activating the parameter list page for

thermal weaving
Parameter list page is not displayed
FALSE
(default)
Thermal weaving
Thermal Weaving
Weave Type
Triangle
Tri..
Weave type
No weave
Triangle
Trapezoid
Weld voltage
*)
Voltage
Volts
Wire Feed
20
Thermal Weave Length
Wire feed rate

*)
Thermal weave length
1.5 to 12 mm
For information about applications in which
thermal and mechanical weaving are
combined, see Section 5.11.

Fig. 24 Parameter list for thermal weaving
The Thermal weaving parameter list shown in Fig. 24 is only displayed if the value of the
variable A_TH_WEAVE_OPT has been set to TRUE.
The distribution of heat can be moved from one side of the metal sheet to the other by
rotating the mechanical weave pattern through 180 degrees.
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The functions of these parameters are only available once they have been configured in
$CONFIG.DAT and the system has been restarted.
Two patterns (triangle and trapezoid) are predefined by the manufacturer, as shown in Fig. 25.
Thermal weaving
Weld voltage
(volts)
Max. voltage *)
(Primary Weld
parameter list)
Min. voltage *)
(Thermal
weaving
parameter list)
Thermal weave
length
L
Weld voltage
(volts)
Max. voltage *)
(Primary Weld
parameter list)
Min. voltage *)
(Thermal weaving
parameter list)
Wire feed rate

(meters/minute)
Max. feed rate *)
(Primary Weld
parameter list)
Min. feed rate *)
(Thermal
weaving
parameter list)
Thermal weave
length
L
Wire feed rate

(meters/minute)
L
Max. feed rate *)

(Primary Weld
parameter list)
Min. feed rate *)
(Thermal weaving
parameter list)
R
Fig. 25 Weave patterns available for thermal weaving
*)The maximum values for weld voltage and wire feed are normally entered in the Primary
Weld parameter list, page 1, and the minimum values in the Thermal weaving parameter
list.
Applications in which mechanical and thermal weaving are combined are described in the
next section 5.11.
Detailed information on thermal weaving can be found in the documentation
In order to ensure synchronization between mechanical and thermal weaving, the variable
$TECH_ANA_FLT_OFF[3]=TRUE has to be set in STEU\$CUSTOM.DAT.
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5.11
Combined mechanical and thermal weaving

The options of mechanical and thermal weaving can also be combined for certain
applications.
The following diagram shows an example of the combination of mechanical and thermal
triangular weaving. By synchronizing the mechanical and thermal weave curves the values
for the mechanical and thermal weave length must be identical the weld voltage and the
wire feed rate are greater on the side of the thicker sheet than on that of the thin sheet.
+
Maximum values for weld voltage

and wire feed rate are entered in
the Primary Weld parameter list,
page 1.
Max. voltage,
max. wire feed
Min. voltage,
min. wire feed
--
90 180
270 360
Minimum values for weld voltage

the Thermal weaving
parameter list.
Mechanical: Triangle
= 0
Thermal: Triangle = 0
Mechanical weaving
Thermal weaving
Fig. 26 Combined mechanical and thermal weaving
The precondition for synchronization is that the values for the thermal weave length
(Thermal weaving parameter list) and the weave length in the Mechanical weaving
parameter list are identical.
You can also shift the phase of the thermal weave curve by 180 in relation to the mechanical
weave curve without difficulty. This is done by entering the maximum values for the voltage
and wire feed in the Thermal weaving parameter list, and the minimum values in the
Primary Weld parameter list, page 1.
As can be seen in the following diagram, the weld voltage and the wire feed rate are, again
in this example, greater on the side of the thicker sheet than on that of the thin sheet.
Min. voltage,
min. wire feed
Maximum values for weld voltage

the Thermal weaving parameter
list.
Minimum values for weld voltage

the Primary Weld parameter list,
page 1.
Max. voltage,
max. wire feed
--
90 180
270 360
= 0
Mechanical: Triangle
Thermal: Triangle = 180
Mechanical weaving
Thermal weaving
Fig. 27 Combined mechanical and thermal weaving
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Further information on mechanical and thermal weaving can be found in the documentation
5.12
Ramp function
The switch from start parameters to weld parameters (start or welding voltage and wire feed
rate) at the end of the start time, i.e. the moment the robot motion begins, normally occurs
without a transition. The switching of weld parameters occurs equally abruptly between
individual ARC SWITCH commands and between ARC SWITCH and ARC OFF.
In certain welding applications for example aluminum welding a gradual transition can
improve the welding results. The ramp function makes it possible to increase or decrease
the weld voltage and wire feed rate within a specified distance the ramp length according
to the parameters set.
If, for example, the start voltage is 30 volts and the weld voltage is 26 volts, the voltage in the
ramp length entered in the Ramp function parameter list is changed linearly from 30 to 26 volts.
A precondition for the ramp function is that the variable A_RAMP_OPTION is set to the
value TRUE.
Variable
Value
Characteristics
FALSE
Ramp function for weld voltage and wire feed

switched off (default).
TRUE
Ramp function for weld voltage and wire feed

switched on.
A RAMP OPTION
A_RAMP_OPTION
The parameter list for the ramp function:

Ramp function
Ramp length
0 to 25 mm
Fig. 28 Ramp function parameter list
If the through--the--arc seam tracking sensor (KUKA.ArcSense) is being used, the ramp
function must not be used! In this case, the variable must be set to A_RAMP_OPTION =
FALSE.
If the distances between points are small, it may be necessary for the system to
execute an exact stop.
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Fig. 29 illustrates the ramp function.

1st seam section
ARC SWITCH
2nd seam section

ARC SWITCH
Weld voltage
26
3rd seam section

ARC OFF
Weld voltage
Weld voltage
23
26
volts
volts
volts
Wire feed rate
Wire feed rate
Wire feed rate
15
15
m/min
Ramp length
12
P1
mm
mm
P4
P3
P2
m/min
Ramp length
Ramp length
mm
Start parameters
(ARC ON)
Weld parameters
m/min
Weld voltage
+
--
Wire feed rate
+
--
P4
P2
P3
P1
Ramp length
Ramp length
Fig. 29 Ramp function

In the first seam section (ARC SWITCH P1 -- P2) the weld voltage changes, after P1 and
within the ramp length (12 mm), from the value set in the start parameter list to the value (26
volts) set in the weld parameter list (ARC SWITCH). The wire feed changes in the same way.
In the second seam section (ARC SWITCH P2 -- P3) the weld voltage can be seen to change
from 26 volts to 23 volts within the ramp length (5 mm) after P2. The wire feed value changes
from 15 to 8 m/min.
In the third seam section (ARC OFF P3 -- P4), the ramp length value is 0 mm. The switch
from the weld parameters for the second seam section to those for the third occurs at P3
without a transition.
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5.13
Extended weld parameter lists for special applications
5.13.1
Additional weld parameter lists

Two analog channels, one for the weld voltage and one for the wire feed rate, are available
as standard for controlling the welding controller. For special applications, the number of
analog channels can be increased by changing the value of the variable A_ACT_AN_MAX=
3 accordingly.
The functions of these variables are only available once they have been configured and the
system has been rebooted. Otherwise, the weld parameter list is not displayed.
For more information, see also the documentation [KUKA.ArcTech Analog -- Configuration].
An additional weld parameter list for applications with three analog channels is shown in
Fig. 30. If the number of analog channels is increased further, the number of additional input
boxes, and thus the structure of the parameter lists, is also increased.
Primary Weld
Primary Weld, page 2
Reserved for parameters of an

additional analog channel
Fig. 30 Additional weld parameter lists
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5.13.2
Parameter list for the end parameters

Standard
The End Set parameter list consists of two pages. The settings for crater filling, the gas
postflow time, and burnback are defined here. Burnback is used for burning off excess wire
and ensures the correct free wire length and an ideal shape for the end of the wire for the
ignition process of the following welding cycle.
Both pages of the parameter list together with the respective ranges of settings are shown below.
End Set
Crater Time
End set, page 1
Crater time
0 to 1.5 seconds
Crater voltage
*)
Wire Feed (Crater Filling)
Wire feed for crater filling

*)
Burnback Time
Burnback time 1)
0 to 1.5 seconds
*)
Value ranges and units vary depending on configuration
1)
Visible if HIDE_BB_TIME = FALSE; hidden if HIDE_BB_TIME = TRUE

For more information, refer to the documentation [KUKA.ArcTech Analog -- Configuration]
Fig. 31 End Set, page 1
End Set
Post Flow Time
End set, page 2
Gas postflow time

0 to 1.5 seconds
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The end crater parameters are only effective when the crater fill time (Crater Time) is greater
than zero. If the value for the crater fill time is zero, the burnback parameters for the last
command executed are used.
Further information on end crater filling and burnback can be found in the documentation
Extended end parameter lists for special applications

Just as with the weld parameter lists, the end parameter lists also change when more than
two analog channels are used.
The end parameter lists (En) for applications with three analog channels are shown below.
If the number of analog channels is increased further, the number of additional input boxes,
and thus the structure of the parameter lists, is also increased.
End Set
End set, page 1
Crater Time
Crater time
0 to 1.5 seconds
Crater voltage *)
13 to 39 V
Wire Feed
Wire feed rate *)

0 to 20 meters per minute
Burnback Time
Burnback time
0 to 1.5 seconds
*) Limits and units dependent on configuration

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End Set
Post Flow Time
End set, page 2
Gas postflow time

0 to 1.5 seconds
Reserved for end parameters of an

additional channel
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Program example
Program example
A simple program example will now be used for a step--by--step demonstration of how the
individual commands available with KUKA.ArcTech Analog can be used. The welded
assembly shown in Fig. 35, consisting of three individual parts, is to be fabricated by means
of two seams.
Welding torch
Start position
ARC ON -- PTP
P8
P1
ARC OFF -- LIN
Seam 2/3
P7
ARC OFF -- LIN
P3
Seam 1
Seam 2/2
Motion
-- PTP
ARC ON -- PTP
P6
P4
P5 Seam 2/1
ARC (SWI)
--LIN
ARC (SWI) -- CIRC

P2
Fig. 35 Welded assembly example
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6.1
Starting welding of seam 1 -- ARC ON
Start position
ARC ON -- PTP
P1
Seam 1
Fig. 36 ARC ON weld command

When you select Technology ! ArcTech Analog ! ARC ON ! PTP, the following
inline form will appear:
You can also correct your original selection (ARC command/motion command, type of
motion ...) by means of this softkey bar. The inline form changes accordingly when a selection
is made. The Cmd Abort softkey can be used to abort the command without saving data.
Now enter the motion and weld parameters into both the inline form and the corresponding
parameter lists.
An overview of both the inline input boxes and the parameter lists can be found in Section
5.6.3.
For the purpose of positioning the welding torch, move it to the position P1 by means of the
Space Mouse or the jog keys. Information on controlling motions of the robot manually can
be found in the chapter [Jogging the Robot].
You can now press the Touch Up softkey. In this case, press the Yes softkey to confirm
the query Touchup (Y/N)? that is displayed in the message window. Alternatively, press the
Cmd OK softkey or the Enter key. The current robot coordinates are automatically saved.
58 of 76
Program example (continued)
The command is ended by pressing the Cmd OK softkey or the Enter key. If touchup has
not yet been performed for the point P1, the current robot coordinates are now automatically
saved. The information message Point P1 created automatically is displayed in the
message window.
The inline form is then closed and the generated program line is inserted into the program
form. The numbers of the following program lines are automatically updated.
6.2
Ending welding of seam 1 -- ARC OFF

As this example only involves welding a straight seam, with the motion and weld parameters
remaining the same, only one ARC OFF command is required. This command contains the
motion, weld and end parameters for the seam.
P1
Seam 1
ARC OFF -- LIN
P2
Fig. 37 ARC OFF weld command
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When you select Technology ! ArcTech Analog ! ARC OFF ! LIN, the following
Now enter the motion and weld parameters into both the inline form and the corresponding
parameter lists.
Overviews of both the inline input boxes and the parameter lists for the ARC OFF
command can be found in Section 5.8.3.
To position the welding torch, move it to the position P2 by means of the Space Mouse or
the jog keys.
You can now save the coordinates for this point by means of the Touch Up softkey or you
can automatically save them by pressing the Cmd OK softkey or the Enter key.
Pressing Cmd OK or the Enter key closes the inline form and the created program line is
inserted into the program form. The numbers of the following program lines are automatically
updated.
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6.3
Moving to seam 2 (PTP) and starting welding -- ARC ON

In order to move from the end point of seam 1 (P2) to the start point of seam 2 (P4) via the
auxiliary point (P3), you can, for example, enter the ARC ON -- CIRC command. Positioning
the welding torch directly by means of a PTP motion might involve the risk of it colliding with
the workpiece.
In this example (Fig. 38), the path is covered by means of two PTP motions, as this type of
motion is normally the quickest. A motion command (PTP with approximate positioning) is
used for the path P2 -- P3 and the path P3 -- P4 is covered by means of the ARC ON -- PTP
command.
P1
ARC ON -- PTP
Seam 1
ARC ON -CIRC
P3
P4
Seam 2
Motion -- PTP
P2
Fig. 38 Moving to seam 2 and starting welding

Insert the motion instruction (P2 to P4).
When you select Technology ! ArcTech Analog ! ARC ON ! PTP, the following
Use the procedure described in Section 6.3. After all of the commands have been entered,
the program form contains the motion command (to point P3) in line 6 and the weld command
ARC ON -- PTP (to point P4) in line 7.
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6.4
Welding seam 2 (up to P8)

Seam 2 contains a straight section (from P4, where welding starts, to point P5), followed by
a circular section (to point P7 via point P6) and finally a straight section (to the end of the seam
P8).
P1
P8
Seam 2/3
ARC OFF
--LIN
P7
P4
Seam 2/2
P6
P5
Seam 2/1
P2
ARC (SWI)
CIRC
LIN
Fig. 39 Welding seam 2 (up to P8)
The first section of the seam is programmed as ARC SWITCH with the LIN motion type
and the second section as ARC SWITCH with the CIRC motion type. The ARC OFF
command with the LIN motion type ends the seam.
Seam section P4 ... P5 -- ARC SWITCH -- LIN
When you select Technology ! ArcTech Analog ! ARC SWITCH ! LIN, the following
After entering the motion and weld parameters and moving to point P5, press the Cmd OK
softkey or the Enter key. The program form is updated accordingly.
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Seam section P5 ... P6 ... P7 -- ARC SWITCH -- CIRC

The following section of the seam also requires the ARC SWITCH command. As the seam
does not run in a straight line, however, but is circular, the CIRC motion type must be
selected.
When you select Technology ! ArcTech Analog ! ARC SWITCH ! CIRC, the
following inline form will appear:
Unlike seams along a straight line, whose end point coordinates are automatically saved
when the command is ended, the auxiliary point coordinates for a CIRC motion have to be
saved by means of Teach Aux.
For this purpose, position the welding torch to the auxiliary point P6 (pay attention to the
orientation during this motion) and press the Teach Aux softkey. Answer the question
Touchup really? with the YES softkey.
Then move the torch to the end point P7 of this seam section; again paying attention to the
orientation. You can save the current robot coordinates immediately using the Teach End
softkey, or press the Cmd OK softkey or the Enter key.
Ending welding of seam 2 -- ARC OFF

The ARC OFF weld command is used for the last section. Use the procedure described
in Section 6.2.
The three commands that were entered last are shown in lines 8, 9, and 10 of the following
screenshot.
63 of 76
64 of 76
Altering existing programs
Altering existing programs

It is possible to alter commands and/or parameters and to delete command lines in an
existing program at any time. Two examples are given below.
7.1
Altering command lines

The procedure for altering command lines is demonstrated below by using a different type
of motion from the end of the first seam (P2) to the point in space P3 from that used in the
program example given above.
The type of motion is to be changed from PTP to LIN.
Move the edit cursor to line 6 (P3) by means of the arrow keys.
Press the Change softkey. The inline form for this command line is opened.
Press the LIN/CIRC softkey. Alternatively, the LIN motion type can also be selected using
the status key at bottom right if the first box on the left (PTP motion type) is active. The inline
form changes accordingly.
Enter the new parameters and then press the Cmd OK softkey or the Enter key. The inline
form is closed and the program form is updated accordingly.
7.2
Deleting command lines

In the following example, a SPOT TECH command has been entered by mistake and now
appears as line 10 in the program form.
This command line is to be deleted. To do so, move the edit cursor to line 10 and press the
Program menu key.
Select Line delete using the arrow key or press the key 1 on the numeric keypad (do not
press Enter). If you answer the request for confirmation in the message window with Yes,
the selected line is deleted and the program form is updated accordingly.
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7.3
Adding commands to an existing program

The procedure for adding commands to an existing program is given below. A further part
is to be added to the welded assembly described in Section 6.
(P3)
P12
ARC ON
--PTP
Motion
--PTP
P4
P3
P2
P9
P10
Motion
--PTP
P11
ARC ON
--PTP
ARC (SWI)
--LIN
ARC (SWI)
--LIN
Fig. 40 Adding commands

For design reasons, the seam for the new part must be welded using different parameters:
it is to be welded as a normal straight seam in the first section and mechanical triangular
weaving is to be used in the second.
There are several ways of achieving this, e.g. the new seam could be welded last. However,
this would not be an efficient procedure for the entire sequence. To optimize execution and
the time taken to perform the operation, it is better to execute the welding process for this
new part immediately after seam 1 has been welded.
The following changes, therefore, have to be made to the program:
-- Alteration of the Motion command (P3)
-- Insertion of the ARC ON command (P9)
-- Insertion of the ARC SWITCH command (P10)
-- Insertion of the ARC OFF command (P11)
-- Insertion of the Motion command (P12)
The modified welded assembly is illustrated in Fig. 41.
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Altering existing programs (continued)
Start position
ARC ON -- PTP
P1
P8
ARC OFF
--LIN
Seam 3/3
ARC OFF
--LIN
P7
P12
Seam 3/2
Seam 1
ARC (SWI)
--CIRC
P6
Motion
--PTP
Seam 3/1
P5
P3
P2
P9
P10
P4
ARC (SWI)
--LIN
Seam 2/1
ARC ON
--PTP
Motion
--PTP
P11
Seam 2/2
ARC ON
--PTP
ARC (SWI)
--LIN
ARC (SWI)
--LIN
Fig. 41 Modified welded assembly
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7.3.1
Description of the alteration

To alter the program, open the program form from the previous section.
7.3.2
Altering the Motion command (to P3)

Move the edit cursor (the blinking vertical line) to line 6 (P3).
Move the welding torch to the new position of the point P3 and press the Touch Up softkey.
When asked if you want to teach this point, answer Yes.
7.3.3
Inserting the welding start for the new seam -- ARC ON

Before opening the menu, make sure that the edit cursor (the blinking vertical line) is on
line 6. Insert the ARC ON -- PTP command for the new point P9. Use the procedure
described in Section 5.6.
7.3.4
Inserting the first section of the new seam -- ARC SWITCH

Select the ARC SWITCH -- LIN command for the first section (from P9 to P10) of the new
seam.
After entering the motion and weld parameters, press the Cmd OK softkey or the Enter key.
The program form is updated accordingly.
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7.3.5
Altering existing programs (continued)
Inserting the second section of the new seam -- ARC OFF

The second section (from P10 to P11) is executed using Mechanical weaving. As the seam
ends at P11, the ARC OFF command is used. Select the ARC OFF -- LIN command from
the Technology menu or by means of the softkey bar.
Enter the motion and weld parameters into both the inline form and the corresponding
parameter lists. To enter the parameters for mechanical weaving, open the Mechanical
weaving parameter list.
Select the desired weave pattern (Triangular weaving in our example) by means of the
bottom right status key. To do so, the Weave type input box must be active. Then enter the
values for the weave length, the lateral deflection (weave amplitude), and the angle of the
torch (weave angle).
Detailed information on mechanical weaving can be found in Section 5.9.
Press the Cmd OK softkey. The program form is updated accordingly.
7.3.6
Inserting a point in space -- Motion

Finally, the motion from the end point of the new seam (P11) to the start of the next seam
(P4) must be programmed. A further point in space (P12) is required between P11 and P4
for this purpose.
After ending this command, alteration of the program is completed. The new commands
appear in lines 7 to 10 of the program form.
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70 of 76
Online optimizing
Online optimizing
Online optimizing is only available in the user groups Expert and Administrator.
In order to activate online optimizing, a program has to be selected.
Online optimizing is selected using the menu function Program ! Modify ! Arc Tech
Online Optimizing. This option is activated with the Enter key, which will place a check mark
to the left of the option.
0 ARC Tech Online Optimizing
1 Point
Once online optimizing has been activated, a yellow cursor appears in the program window
and the first command line is highlighted in yellow. Override is deactivated at the same time.
Online optimizing is possible in modes T1, T2, and AUT, but not in EXT.
When, during program execution, ARC SWI or ARC OFF commands arise, a specially
defined parameter list is opened in which the modifications can then be carried out.
Every time a program is aborted or reset, the online optimizing function is deactivated and
the last override value for correction motion is restored.
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8.1
Function overview
Settings can be made for the following:
Online Optimizing
Online Optimizing
Travel Speed
Weave Length
Voltage
Weave Amplitude (zero to peak)

Volts
Wire Feed
8.2
Modification of the parameters

The process changes are reworked depending on the keys pressed. If several changes are
made to one parameter within the space of one second, only the last change is activated as
the processing takes a certain amount of time.
The modified parameters are automatically saved in the event of a block change. Parameters
modified during welding are automatically written to the parameter lists without request for
confirmation.
8.2.1
Modifying the velocity

When online optimizing is activated, the override function is deactivated; the velocity is set
internally to 50% and the weld velocity (travel speed) is doubled.
Example based on the weld velocity in the parameter list displayed above.
If the online optimizing function had not been activated, the 0.5 m/min displayed above
would be realized with an override of 100%.
With online optimizing selected, however, the general override is set in the background to
50% and, in order to enable optimization, the weld velocity is increased in the background
to 1 m/min.
At most, the weld velocity can be doubled or reduced to 1% of the original value. The actual
override varies in accordance with the modification to the weld velocity. The velocity
parameters are always read and processed in the advance run.
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Online optimizing (continued)
In online optimizing mode, changing the velocity also influences the acceleration
characteristics. For this reason, online optimizing mode is only suitable for the start--up
process or for adapting the weld parameters.
8.2.2
8.2.3
Velocity modification limitations

--
It is not possible to modify the velocity in DRY RUN mode.

This is because the velocity in the constant phase does not correspond with the
process velocity.
The MIN value is the same here as the MAX value and no modification is accepted.
--
If online optimizing is activated in the middle of a program, it is not possible to

change the velocity. Modification only becomes possible again once new ARC
commands have been processed in the advance run.
Deselecting the online optimizing mode

To deactivate online optimizing, press the Program menu key again. Select Online
optimizing again by highlighting the function using the arrow keys and pressing the Enter
key. The check mark in front of the function should now no longer be visible.
After the online optimizing mode has been deselected, the override should be adapted.
8.2.4
Block selection response

If the editor detects the commands without knowing whether or not the advance run has
correctly processed the velocity, the velocity modification function may be disabled. The
response depends on the individual system.
8.2.5
Modifying the weld voltage

This process parameter can be changed at any time. The values are scaled in accordance
with the characteristic curve set for the power source and sent to the relevant analog output.
73 of 76
8.2.6
Modifying the wire feed

This process parameter can be modified in any situation. The values are scaled in
accordance with the characteristic curve set for the power source and sent to the relevant
analog output.
With TRACK commands, modification of the wire feed should be prevented. If this is not
done, it is possible that the sensor may feed sensor information to the torch causing the torch
to move away from the component when the wire feed is incremented.
The following modification must be made in A10 Globals in $CONFIG.DAT:
Default
The value of the variable A_SYNERG_OPT (power sources with correction channel) can
be set to TRUE, thus influencing the specified channel.
8.2.7
Modifying the weave parameters

The weave parameters can also be modified in DRY RUN mode, but no weave is activated
in this mode.
The weave amplitude can be modified within the limit values at any time.
In the case of the weave length, however, the dependence of this parameter on the velocity
must be taken into consideration.
Further information on the relationships between the parameters may be found in the
chapter [Mechanical weaving], in the section 5.9.1 Weave frequency, weave length, path
velocity.
8.3
Interrupt response
If a modification is made, e.g. after a fault, it takes effect either immediately (start time = 0)
or after the ignition process (start time > 0). Precondition:
The following modification must be made in $CONFIG.DAT:
The variable A_WEAV_GEN[3]
has the default value 3 and
must have this value in the
event of optimizing.
If, in the event of online optimizing, this variable has the value 0, the following message
is generated in the message window: No cyclical analog outputs activated -- and no
changes can be made to the analog channels.
74 of 76
8.4
Override for correction motions
System response
The time taken to generate and remove the parameter lists is determined by the available
computing time and memory capacity.
A memory capacity of at least 64 MB and a Celeron processor with a clock frequency
of 400 MHz or higher are recommended.
Override for correction motions

When the program is executed after a Reset, a note will appear in the message window
(except when in Automatic External mode) requesting confirmation of the override at 100
percent, if it is currently < > 100 percent.
If the Yes softkey is pressed, the override is set to 100%.
If you press the No softkey, the current override value is retained. This means that the
motion between the weld seams is slower, in accordance with the value currently set for the
override.
9.1
Restrictions
--
Due to the reduction of the override, the weld velocity can only be increased as
far as the path velocity limit data. A corresponding message is displayed.
--
The reduction of the override changes the acceleration characteristics of the

robot. The lower the override, the slower the acceleration.
In production mode, the override should always be set to 100%.

In online optimizing mode, changing the velocity also influences the acceleration
characteristics. For this reason, online optimizing mode is only suitable for the start--up
process or for adapting the weld parameters.
75 of 76
9.2
Correction motion override and online optimizing

With a general override < > 100%, an online optimizing situation may arise.
If this is the case, the correction motions are carried out more slowly, according to the
generally lower override previously set. The weld motions are then executed in online
optimizing mode with an override of 50% and with the weld velocity doubled.
The velocity of the selected correction motion will remain the same.
10
Customization
Further software settings can be made in order to ensure optimal adaptation to the specific
requirements of the customer:
G
Application--specific headings can be given to the parameter lists and units of the start,
weld and end crater parameters for each of the analog channels used.
For more details, refer to the documentation [KUKA.ArcTech Analog -- Configuration]
The customer--specific settings are saved in the KUKA_CON.MDB file.
Adaptations relating to burnback times can be removed from the display.
Reinitialization mechanisms for programming increments and units in the parameter list
display.
In addition, there is the option of creating dynamically generated error messages, which can
be adapted to the application that is running. This means that it is possible to break down
a standard group error message and generate separate specific messages.
The configuration is saved in the ARC_MSG.SRC file. This greatly simplifies any
troubleshooting that may be necessary during operation.
1
76 of 76
Index
Symbols
D
Delay of weld start, 28
Deleting command lines, 65
Double 8, 43
DRY, 17
#ACT_PAR, 19
$TECH_ANA_FLT_OFF, 49
A
A_ACT_AN_MAX, 10, 53
E
End Set, 54
A_AP_DIS_TCH=5.0, 31, 33
A_BB_MODE, 10, 19
A_RAMP_OPTION, 10, 51
A_RAMP_OPTION = TRUE, 34, 39
Figure--eight weaving, 43
Function overview, 72
A_TH_WEAVE_OPT, 10, 48
A50_OPTION (KUKA.ArcSense), 10
Adding commands, 66
Altering command lines, 65
Gas postflow time, 54

Gas preflow time, 23, 25, 27, 28
Amplitude, weaving, 44
ARC OFF, 8, 35, 59
ARC OFF CIRC, 37
ARC OFF LIN, 36
H
HOT/COLD, 17
ARC OFF weld and end parameters, 38, 39

ARC ON, 8, 22, 58
ARC ON CIRC, 27
I
INI, 8
Inline form, 16
Installation, 13
Interrupt response, 74
ARC ON LIN, 25
ARC ON PTP, 23
ARC SWITCH, 8, 29, 62
ARC SWITCH LIN, 30, 32
ARC SWITCH weld parameters, 34
K
KUKA.ArcSense, 40
B
Basic settings, 19
Block selection response, 73
LIN, 22
Burnback mode, 19
Burnback time, 39, 41, 54
C
CIRC, 22
Combined mechanical and thermal weaving,
50
Controlling welding, 17
Crater time, 39, 54
Crater voltage, 39
Index -- i
M
Maximum weave frequency, 46
Mechanical weaving, 42, 69
Menu keys, 15
Modification of the parameters, 72
Modifying the weave parameters, 74
Modifying the weld voltage, 73
Modifying the wire feed, 74
Motion characteristics of the robot, 46
Motion type, 22
Index
T
Nomogram, 45
Thermal weaving, 48
TRACK, 40
Trapezoidal weaving, 43
Online optimizing, 71
Override for correction motions, 75
Triangular weaving, 43
Type of motion, 16
P
Parameter list for start parameters, 28
Parameter list for the end parameters, 54
Parameter list for weld parameters, 34
Parameter list for weld parameters (W), 41
Peripheral equipment adaptation, 19
Periphery, 19
Primary Weld (weld parameters), 41
Program run mode, 19
PTP, 22
U
Uninstallation, 13
Variables in inline forms, 21

Ramp function, 51
Resonant frequency, 46
Rotation of the weave plane, 46
S
Seam sections, 29
Sensor, 40
Softkeys, 16
Spiral weaving, 43
Start parameters, 23, 25, 27
Start time, 23, 25, 27, 28
Start voltage, 23, 25, 27, 28
Start welding -- ARC_ON, 22
Status key +, 17
Status key --, 17
Status key DRY, 18
Status key HOT/COLD, 17
Status keys, 15
System response, 75
Velocity modification limitations, 73
W
Weave amplitude, 42
Weave angle, 42
Weave frequency, 45
Weave length, 44, 45
Weave type, 42
Weld velocity, 41, 45
Weld voltage, 41
Wire feed, 17, 23
Wire feed rate, 25, 27, 39, 41
Wire feed rate at start, 28
Index -- ii

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SOFTWARE

KUKA.ArcTech Analog -- Operation

Issued: 14 Dec 2005

KUKA Roboter GmbH

Brief description of the commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional safety instructions for KUKA.ArcTech Analog . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols and icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The graphical user interface - KUKA Control Panel (KCP) . . . . . . . . . .

Function of the menu keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic settings; peripheral equipment adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program run mode for welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creating a program for ArcTech Analog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variables in input boxes of the inline forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start welding -- ARC_ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welding several seam sections -- ARC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welding and ending a seam (ARC OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KUKA.ArcTech Analog -- Operation

Combined mechanical and thermal weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Extended weld parameter lists for special applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting welding of seam 1 -- ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ending welding of seam 1 -- ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving to seam 2 (PTP) and starting welding -- ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . .

Welding seam 2 (up to P8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Altering existing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Altering command lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Deleting command lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding commands to an existing program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Modification of the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Override for correction motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Correction motion override and online optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KUKA.ArcTech Analog -- Operation

Arc start parameters

Arc weld parameters

Arc end parameters

Fig. 1 Structure of KUKA.ArcTech Analog commands

KUKA.ArcTech Analog -- Operation

Brief description of the commands

KUKA.ArcTech Analog -- Operation

Additional parameter list element, displayed

Appearance of the parameter list page

Appearance of the parameter list with

For setting options, see Section 5.6

The safety instructions in the KR C2 Operating Handbook must be observed.

Additional safety instructions for KUKA.ArcTech Analog

Installation, exchange, and service work on this technology package or individual

KUKA.ArcTech Analog -- Operation

Symbols and icons

Installing the software

Installing the software

The following three options are available for selection:

ArcTech Analog (Thin)

ArcTech Analog (Thick)

ArcTech Analog (Thick with TAST Sensor)

The KUKA.ArcSense through--the--arc seam tracking sensor, which is only available if

KUKA.ArcTech Analog -- Operation

The graphical user interface -- KUKA Control Panel (KCP)

The graphical user interface - KUKA Control Panel (KCP)

Function of the menu keys

Configure menu, Status keys

Fig. 2 Activating status keys for KUKA.ArcTech Analog

KUKA.ArcTech Analog -- Operation

Function of the Technology menu key