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GMNA Controls, Conveyors, Robotics & Welding

Servo Gun Setup Manual


Fanuc SpotTool+ 7.20 with GRS4 Customization

October 10, 2007

Rev 1.0
DOCUMENT MANAGEMENT INFORMATION

Authors:

Andrew Buckland: General Motors CCRW


Chad Lare: Extreme Automation
Prateek Mishra: General Motors CCRW
Lloyd Steed: Fanuc Robotics N.A.
Rob Totten: General Motors CCRW

Sponsoring group:

General Motors -Controls, Conveyors, Robotics and Welding, CCRW

Forward questions, comments and/or revisions to:

General Motors Corporation


Controls, Conveyors, Robotics & Welding
30300 Mound Road 109
Mail Code 480-109-266
Warren, MI 48090
Attn: Prateek Mishra
Phone #: (810) 602-8295

Document revisions:

Date Revision By Revision History


10-Oct-07 1.0 PM Clarifications and corrections and remove “Draft”.
Remove section on Tip Dress. Refer tip dress
manual.
7-Dec-06 0.14 RLT First Draft
10-31-2005 0.10 RLT Start of Rework to convert SpotTool+ 6.40 Manual
to SpotTool+ 7.20
Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
Customization
TABLE OF CONTENTS

Section Description Page

1. GENERAL ............................................................................................................................................ 1
1.1 SCOPE.............................................................................................................................................. 1
1.2 PURPOSE.......................................................................................................................................... 1
1.3 INTENDED AUDIENCE....................................................................................................................... 1
1.4 BACKGROUND ................................................................................................................................. 1
1.5 SETUP FLOW.................................................................................................................................... 2
2. GUN INSTALLATION........................................................................................................................ 3
2.1 GUN MOUNTING .............................................................................................................................. 3
3. WIZARD SETUP ................................................................................................................................. 4
3.1 GETTING STARTED .......................................................................................................................... 4
3.2 EXAMPLE: SINGLE CARRIED SERVO GUN ........................................................................................ 4
3.3 HELPS AND HINTS ........................................................................................................................... 6
3.3.1 Re-Running the wizard to correct for an incorrect response during initial setup .................. 6
3.3.2 Re-Running the wizard to add a feature ................................................................................. 6
4. ESTABLISHING PULSE ON SERVO GUN MOTORS .................................................................. 7
4.1 RESETTING BZAL (BATTERY ZERO ALARM) .................................................................................. 7
4.2 ESTABLISHING PULSE ...................................................................................................................... 7
4.2.1 GSWA and SW-Series Motors................................................................................................. 7
4.2.2 HT-Series Motor ..................................................................................................................... 7
5. MASTERING THE GUN .................................................................................................................... 8
5.1 SETTING GUN CLOSE DIRECTION .................................................................................................... 8
5.2 MASTERING THE GUN AND SETTING AXIS LIMITS ........................................................................... 9
5.2.1 Single Gun per Equipment...................................................................................................... 9
5.2.2 Dual Guns on One Equipment (Typically Dual Carried or Dual Pedestal)......................... 11
5.3 AUTOTUNING ................................................................................................................................ 13
5.3.1 Running................................................................................................................................. 13
5.3.2 Help and Hints...................................................................................................................... 15
6. PRESSURE CALIBRATION............................................................................................................ 17
6.1 EQUIPMENT ................................................................................................................................... 17
6.2 PERFORMING CALIBRATION .......................................................................................................... 17
6.3 HELP AND HINTS ........................................................................................................................... 21
7. THICKNESS CHECK CALIBRATION.......................................................................................... 22
8. TIP WEAR COMPENSATION ........................................................................................................ 24
8.1 SETUP ............................................................................................................................................ 24
8.1.1 Enabling Tip Wear Compensation........................................................................................ 24
8.1.2 Running Tip Wear Compensation Setup Program(s) ........................................................... 26
8.1.3 Wear Ratios .......................................................................................................................... 26
8.2 VIEWING TIP WEAR VALUES ......................................................................................................... 26
8.3 TIP WEAR UPDATING .................................................................................................................... 28
8.3.1 Tip Wear Routines ................................................................................................................ 28
9. SET GUN CLOSE DIRECTION ...................................................................................................... 29
9.1 CARRIED +Z ................................................................................................................................. 29
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Customization
9.1.1 Single Gun ............................................................................................................................ 29
9.1.2 Dual Gun Single Equipment ................................................................................................. 30
9.2 PEDESTAL +Z ................................................................................................................................ 30
9.2.1 Single Gun ............................................................................................................................ 31
9.2.2 Dual Gun Single Equipment ................................................................................................. 31
10. PRESSURE SCHEDULES ............................................................................................................ 33
10.1 BACKGROUND ............................................................................................................................... 33
10.2 ELEMENTS ..................................................................................................................................... 33
10.2.1 Weld Force ........................................................................................................................... 34
10.2.2 Part Thickness ...................................................................................................................... 34
10.2.3 Gun Sag ................................................................................................................................ 35
10.2.3.1 Enabling........................................................................................................................ 35
10.2.3.2 Setup ............................................................................................................................. 36
10.2.4 Pushing Depth ...................................................................................................................... 37
10.2.5 Contact Speed ....................................................................................................................... 38
11. BACKUP SCHEDULES ................................................................................................................ 40
12. DISTANCE SCHEDULES ............................................................................................................ 41
13. PROGRAM LISTINGS ................................................................................................................. 42
13.1 STYLE TEMPLATES ........................................................................................................................ 42
13.1.1 Carried Servo Gun................................................................................................................ 42
13.1.2 Single Pedestal Servo gun No Tip Dress .............................................................................. 43
13.1.3 Dual Pedestal Servo Gun No Tip Dress ............................................................................... 44
13.1.4 Single Pedestal Servo gun With Tip Dress ........................................................................... 45
13.1.5 Dual Pedestal Servo Gun With Tip Dress............................................................................. 46
13.2 MISCELLANEOUS SERVO GUN MACROS ........................................................................................ 47
13.2.1 Stepper Check ....................................................................................................................... 47
13.2.2 CAP_WEAR .......................................................................................................................... 48
13.2.3 Number of Guns.................................................................................................................... 49
13.2.4 TW_GUNS ............................................................................................................................ 50
13.2.5 Tip Reset ............................................................................................................................... 51
13.2.6 Cap Select............................................................................................................................. 52
14. RECOVERY ................................................................................................................................... 53
14.1 RECOVERY FROM LOSS OF MASTERING......................................................................................... 53
14.1.1 Mastering the Gun from the Master/Calibrate screen.......................................................... 53
14.2 CAP CONFIGURATION CHANGE ...................................................................................................... 54
14.2.1 Re-Run the wizard ................................................................................................................ 54
14.2.2 Mastering the Gun and Setting Axis Limits .......................................................................... 54
14.2.3 Running Tip Wear Setup....................................................................................................... 54
14.2.4 Completing Pressure Calibration......................................................................................... 54
14.2.5 Path Touch up....................................................................................................................... 55
14.3 MOTOR REPLACEMENT ................................................................................................................. 55
15. VARIABLE LISTING ................................................................................................................... 56
16. COMMON ERRORS ON SERVO GUN ERRORS .................................................................... 57
16.1 SRVO-023: SERVO STOP ERROR EXCESS (G:%D A:%D)............................................................. 57
16.2 SRVO-024: SERVO MOVE ERROR EXCESS (G:%D A:%D) ........................................................... 57
16.3 SRVO-069: SERVO CRCERR ALARM (GRP:%D AX:%D) ........................................................... 57
16.4 SRVO-062: SERVO BZAL ALARM (GROUP:%D AXIS:%D)......................................................... 57
16.5 SRVO-068: SERVO DTERR ALARM (GRP:%D AX:%D).............................................................. 57
16.6 SVGN-023: INCOMPLETE PRESSURE CALIBRATION ...................................................................... 57
16.7 SVGN-024: INCOMPLETE WEAR DOWN CALIBRATION ................................................................. 58

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Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
Customization
16.8 SVGN-032: TIP INCREASED ERROR ............................................................................................... 58
16.9 SVGN-118: MAX WEAR EXCEEDED .............................................................................................. 58
16.10 SVGN-020: PRESSURE SHORTAGE ............................................................................................ 58
16.11 HOW TO CHECK GUN IMPEDANCE: ............................................................................................. 59

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Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
Customization
1. General
1.1 Scope
The following documentation is intended to be a reference document to aid in the setup and
installation of the robotic servo weld guns for all project using servo guns and Fanuc SpotTool+ 7.20
with the GRS4 Customization. This documentation is intended to detail the steps necessary to install
a Tolomatic servo weld gun on to a Fanuc R-2000iB R-30iA robot. The steps outlined in this manual
will allow the intended audience to install the weld gun, calibrate and tune, and program/touchup weld
paths.

1.2 Purpose
The steps outlined in this manual will help to ensure that all servo weld guns are integrated
and setup in the same fashion so that the system is easily maintained and is fully functional to all RS
specifications as well as GCCS-2, and GCCH-1. This document is not intended to replace servo gun
manuals from Fanuc, but to simply document specific setup criteria specific to General Motors
applications, using Fanuc SpotTool+ 7.20 with the GRS4 Customization.

1.3 Intended audience


The intended audience for this document is, the robot programmers, engineers, and skilled
trades that will be responsible for setting up the servo gun robots at integration, and maintaining the
equipment once it is installed into the production environment.

1.4 Background
The servo guns that are being utilized use a Tolomatic motor that incorporates a Fanuc
encoder, and connectors that allow it to be controlled by the Fanuc robot. There are 5 different motor
sizes.
1. HT-12, which is capable of generating 1200 lb of force
2. HT-23 which is capable of generating 2300 lb of force
3. SW-44 that is capable of 2500 pounds of force
4. GSWA-101(Global C-Gun Actuator) that is capable of 2500 pounds of force
5. GSWA-102(Global Pinch Gun Actuator) that is capable of 2500 pounds of force
6. GSWA-103(Global X-Gun Actuator) that is capable of 2500 pounds of force
Note: The GSWA-102 and GWSA-103 are electrically identical, and only vary on there
mounting features. Therefore they share the same parameters in the robot.

All motors are driven by the same 40 amp auxiliary amplifier in the robot, as an integrated robot axis.
The basic setup has the robot arm as motion group 1, and the servo guns as group 2, and group 3 if
necessary. The control of the servo gun is integrated into the robot system, such that I/O is not
necessary to control the gun functionality, such as backup or equalization.

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Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
Customization
1.5 Setup Flow

The following flow chart is a process of the steps necessary to setup a servo gun robot

Confirm
Mount & Connect Section
connectors
Gun 2
are clear

Setup Run Controlled Section


Application Wizard Start 3
Perform Cold Start

GSWA-101 Reset Section


GSWA-102 Pulse code 4
GSWA-103 Faults

Master & Set Section


New caps 5
Menu Utilities Limits
Auto Tune Done in Test
Cell Prior to
Integration if
Perform Section
T1 Possible
6
Pressure Calibration 100%

Section
Perform 7
Thickness Calibration

Section
Run Tip Wear Setup New Caps
8
Setup Macro Tip Wear

Section
Gun - Moveable Set Carried: +Z
9
Robot - Stationary Pedestal: +Z
Gun Close Direction

Section
Setup
10
Pressure Schedules
Section
Enable / Disable 11
Desired Setup
Schedules within Back up Schedules
Gun Range
Section
Teach-Touch up Touch 12
to
Path Metal

Tip Dress
Setup

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Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
Customization
2. Gun installation
2.1 Gun Mounting

When mounting the gun to the robot faceplate, care should be given to the way the
connectors for the motor will route. There are 2 connectors that are used to control the Tolomatic
motor from the robot. The first is the power cable and the second is the encoder cable. These
should be positioned such that the cables and connectors are in the safest location relative to
projected path. If there is an interference, it is possible to rotate the motor end cap +- 90°. See motor
documentation on rotating the connectors on the end cap.

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Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
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3. Wizard Setup

The wizard allows the robot software to be configured for the specific application. The
programmer needs only answer a few questions and the software configures itself based on the
answers chosen by the programmer. This functionality has been further enhanced to include setting
up of the servo gun applications, including group and axis data that previously needed to be done
manually before running the wizard. This presented some complexity issues and has been remedied
by adding the necessary functionality to the wizard.

3.1 Getting Started

Before running the wizard there are a few things that need to be known about the robot and
application. They are as follows:
1. Robot software version.
• Must be 7.20/P19 with GRS4 Customization dated 01/06/2007 or later.
• An update will be necessary if the software is not up to this level.
2. Information about the application that the robot performs
• Carried or Pedestal Process
3. Information about the servo guns
• Motor Type
• Maximum Force for the gun (NOT the maximum motor force)
• Net Gear Ratio (NOT the motor ratio)
• Maximum gun opening (NOT the maximum motor stroke)
• Gun type: Pinch/X-style or C-style
• Auxiliary Amplifier that the servo motor is attached to
4. Information on how the guns are going to be used (If multiple guns exist)
• Dual gun single equipment
• Dual gun Dual equipment, 1 or 2 weld controllers
a. Affects tip wear compensation and pressure schedule approach.

If the appropriate groups are not present when the wizard is run, the wizard will automatically
add the Servo Gun group and then boot back to controlled start. Once the robot has returned to
Controlled start it will be necessary to re-run the wizard to configure the robot application. The
following shows the steps necessary to configure a single carried servo gun. Other applications
follow a similar setup, and the user should be able to configure for other applications by simply
following the provided prompts.

3.2 Example: Single Carried Servo Gun

Wizard Execution: (Single Carried Servo Gun)

1. Perform Controlled Start


2. Place a full load memory card with the AP1 directory into the controller
• This will allow the wizard to load a Servogun Axis as group 3 for multi equipment
configurations.
3. Scroll to item 1[Setup Wizard] and press [F4: ENABLED]
4. Answer [YES] to the prompted question “HAS THE I/O BEEN BACKED UP?”
5. At the “GRS4 CUSTOMIZATION” menu, press [1: START SETUP WIZARD], then press
[ENTER].
6. At the “Select Manufacturing Area”, Press [1:Bodyshop]
7. Press [1: SPOTWELDING], then pre1ss [ENTER].
8. Press [1: ONE WELD CONTROLLER], then press [ENTER].
9. Press [1: EthernetIP], then press [ENTER].
10. Press [1: ROBOT HELD GUN], then press [ENTER].
11. Press [1: YES], then press [ENTER], when asked if the gun is a servo gun.

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12. The wizard will then ask what motor type is attached to the servo gun
• Answer [1: Tolomatic SW 44] then [ENTER] for the SW/44 motor.
• Answer [2: Tolomatic HT 23] then [ENTER] for the HT/23 motor.
• Answer [3: Tolomatic HT 12] then [ENTER] for the HT/12 motor.
• Answer [4: SWGA C-Type] then [ENTER] for the Global C-motor.
• Answer [5: SWGA X/P Type] then [ENTER] for the Global X/P-motor.
• See motor tag for motor type
13. The wizard will then ask to enter the Gear Ratio for the gun
• Enter the gear ratio of the gun (mm/rev) from the GUN tag, not the motor tag and
then [ENTER].
14. The wizard will then ask to enter the maximum weld gun force for the servo gun
• Enter the maximum weld pressure (N) of the gun from the GUN tag, not the motor
tag and then [ENTER].
15. The wizard will then ask to enter maximum gun opening distance for the servo gun
• Enter the maximum opening distance of the gun (mm) from the GUN tag and then
[ENTER].
16. The wizard will then ask what style the servo gun is
• Answer [1: C Gun Type] then [ENTER] if the gun is a C-style gun.
• Answer [2: X Gun Type] then [ENTER] if the gun is an X-style gun.
17. The wizard will then ask what amplifier the servo gun is attached to.
• The servo gun will typically be attached to amplifier #2
• Guns 1 and 2 are typically on Amplifier #2
• Guns 3 and 4 are typically on Amplifier #3
• Enter [2] then [ENTER] (May be 3 for robots with more than 2 guns)
18. The wizard will then ask if transformer overtemp is used for the gun
• Answer [1: YES] then [ENTER] if the transformer has an overtemp switch wired in
.
• Answer [2: NO] then [ENTER] if the transformer does NOT have a transformer
overtemp wired in.
19. The wizard will then ask if the gun has a tip dresser.
• Answer [1: YES] then [ENTER] if there is a tip dresser for the gun.
• Answer [2: NO] then [ENTER] if there is no tip dresser.
20. If you answered yes to the question of does the gun have a tip dresser, you will be prompted
for the tip dresser motor starter model
• Answer [1: ECS 1085/1086] then [ENTER] for legacy motor starters
• Answer [2: ARMORSTART] then [ENTER] for Global Motor Starters
21. If you answered yes to the question of does the gun have a tip dresser, you will be prompted
if you want to tip dress after a cap change
• Answer [1: YES] then [ENTER] if you want to tip dress after a cap change.
• Answer [2: NO] then [ENTER] if you do not want to tip dress after a cap change.
• The plan is to predress the new global weld caps, so the answer should always be
Yes.
22. You will then be prompted if you have a Tool Changer.
• Answer [1: YES] then [ENTER] if the robot has a tool changer
• Answer [2: NO] then [ENTER] if the robot does not have a tool changer
23. You will then be prompted if you would like to set up the pressure and backup tables for the
gun.
• Answer [1: YES] then [ENTER] if this is the first time the robot has been setup.
This will load the default servo gun pressure schedules, but will not overwrite the
actual pressure values.
• Answer [2: NO] then [ENTER] if you have made changes to the servo gun
pressure schedules and do not want them overwritten with the defaults.
24. You are now back at the GRS4 CUSTOMIZATION SCREEN. Press [2: Set Cell I/O to PLC]
then [ENTER] to launch the “SET CELL I/O ” functionality.

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25. Press [1: EthernetIP], then press [ENTER] twice.
26. You are now back at the GRS4 CUSTOMIZATION SCREEN. Press [4: Exit] then [ENTER]
twice to close the wizard.
27. Press [FCTN] -> [ENTER], to Cold Start the robot.

3.3 Helps and Hints

3.3.1 Re-Running the wizard to correct for an incorrect response during initial setup

If a mistake was made in the initial setup of the wizard, the easiest way to recover is to re-run
the wizard. This will allow the robot to automatically reconfigure for the change. There is no need to
reboot back to controlled start if you are currently at controlled start. Simply re-run the wizard making
sure to take your time. It is necessary to set Cell I/O every time the wizard is run as the robot resets
the cell interface to default when the wizard is launched.

3.3.2 Re-Running the wizard to add a feature

If it is necessary to add a feature such as a tip dresser or Transformer Over Temp, it is not
necessary to re-run the wizard completely. It is necessary however to Boot to Controlled start and
launch the Wizard, selecting Item #3 ‘Add to Configuration’. This will allow the user to add the
necessary items, without having to run through the entire wizard. Prior to adding a feature, it is best
to back up the robot, incase an error occurs. A backup all is sufficient

1. Perform a Backup All of the controller


2. Perform a Controlled Start
3. Start the wizard
a. Select Option #3 ‘Add to Configuration’
i. Follow the prompts as necessary
4. Perform a cold boot
5. Query any new DeviceNet nodes as necessary.

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Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
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4. Establishing Pulse on Servo Gun Motors

Once the groups and axis are configured, and the wizard run, it is necessary to master the
guns. This procedure is critical, and must be followed as outlined below. The steps outlined below
need to be followed for each configured servo gun.

4.1 Resetting BZAL (Battery Zero Alarm)

As is the case any time a motor is installed on the robot it will be necessary to clear the BZAL
alarm that indicates that the system has lost communication with the encoder.

The steps necessary for clearing the BZAL alarm:

1. Press [MENUS] -> [NEXT] -> [SYSTEM] -> [Master/Cal]


2. Press [FCTN] ->[3: CHANGE GROUP] (Select the Servo Gun group, either 2 or 3)
3. Press [F3: RES PCA]
4. Select [F4: YES] when prompted to ‘Reset pulse coder alarm?
5. Repeat steps 2 and 3 for all servo gun groups.
6. Cycle the power on the robot controller.
7. SRVO-075 Pulse not established will be displayed in the fault log upon power up.

4.2 Establishing Pulse

Before the Gun can be mastered it is necessary to establish pulse with the Fanuc Encoder
that is mounted in the Tolomatic motor.

4.2.1 GSWA and SW-Series Motors

The method used to establish pulse on the SW series motor is identical to the method used
to master a standard Fanuc motor.

1. Select Group 2 for equipment 1, Group 3 for equipment 2


a. Press [FCTN]
b. Item [3: Change Group]
2. Jog Servo Gun axis until pulse is established. (The robot may indicate on the teach
pendent that 'Pulse has been Established')
a. Jog the axis in both the +X and -X direction until 'Pulse is
established'
b. For a second gun on that equipment jog the second axis in the +Y
and -Y direction until 'Pulse is established'.
4.2.2 HT-Series Motor

For the HT-series motors, because they are 4-pole rather than an 8-pole require an additional
step to establish pulse with the encoder. It is not possible to immediately jog the axis without
manually rotating the motor by hand.

To establish pulse on the HT-Series motors it is necessary to perform the following for each gun:
1. Locate the manual override key/gear on the servogun actuator.
2. Loosen the cover and slide out of the way. (Do not remove completely)
3. Using a screwdriver carefully rotate gear one complete revolution.
4. Attempt to jog the gun.
i. If successful, the gun will move, and the gun can then be mastered
ii. If unsuccessful, the robot will still indicate a pulse not established alarm.
Repeat step 3 and 4 until successful.
5. Replace cover on manual override access .

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5. Mastering the Gun

This is the recommended method to master the weld gun, because it calibrates the axis
automatically and sets the servo gun limits to the limit defined in the Wizard setup at controlled start.
This method also verifies that the gun close direction is correct such that there is commonality among
all guns and for the capability to download simulations.

To access the Gun Setup and Autotuning screen :

Press [MENUS] -> [Utilities] -> [TYPE] -> [Gun Setup]

The following
steps must be
completed in
order.

5.1 Setting Gun Close Direction

The first step in calibrating the gun is to set the gun close direction. This is to set the robot up
such that +X on the teach pendent closes the gun. Follow the directions and then proceed to the next
step.

1. Select [Set Gun Motion Sign], and follow instructions

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Note:
For all GM servo guns we want +X to close the gun tips and -X to open the gun (+Y/-Y for the
second gun on an equipment). If this is not the case, as with reverse parallel guns, it will be
necessary to go into controlled start and to change the motion sign under the axis configuration from
False to True. This should only be the case on reverse parallel guns.

5.2 Mastering the Gun and Setting Axis Limits

5.2.1 Single Gun per Equipment

1. Select [Set Gun specs, master gun]

2. Answer [YES] When prompted if you know the gun’s tip displacement of the gun (Gear
Ratio from the gun tag)

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3. Answer [YES] When prompted if you know the gun’s stroke limits (Gear Ratio from the
gun tag)
4. Follow the directions to master the gun and set limits
• Close the Gun until the caps are touching and Press [F4:Closed]
• Enter the Tip Displacement (This is the Value that was entered in the Wizard at
controlled start)

This will actually


master and calibrate
the gun at once,
allowing you to jog the
gun open to the axis
limit that was set off
the gun tag at
controlled start.

5. Enter the Open and Closed limits for the weld gun.
• The open limit is the value that was entered at controlled start. The closed limit
is 20mm for all guns

6. Press [F3:COMP] when complete

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7. It is now necessary to Autotune the motor.

5.2.2 Dual Guns on One Equipment (Typically Dual Carried or Dual Pedestal)

Because of the way Fanuc handles Dual guns on 1 equipment, it is necessary to master both
guns together even thought they each have their own Servo Gun Tune screen. The following will
outline the steps necessary to Setup dual guns as a single equipment.

1. Select [Set Gun Specs, Master Gun] for Gun 1

The EQUIP The INDEX


button is used to button is used to
switch between switch between
guns on different guns on the
equipment same equipment

2. Answer [YES] When prompted if you know the gun’s tip displacement of the gun (Gear
Ratio from the gun tag)

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3. Answer [YES] When prompted if you know the gun’s stroke limits (Gear Ratio from the
gun tag)
4. Follow the directions to master the gun and set limits with the following changes
• Both guns associated with the active equipment must be mastered together
• Jog both guns closed before selecting F4 at step 1.
• Enter the Tip Displacement and Limits
Jog both guns
associated with the
active Equipment to
the closed position.
Then F4 is pressed it
will master and
calibrate both guns
associated with the
Equipment, not just
the active gun

5. Repeat steps 1 - 3 for the other gun on the active equipment.


• Use the Index button to switch between guns on the same equipment

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• This is necessary to get the gun 2 screen to indicate that everything is set.
• This is easily accomplished by using the backup keys and closing the backups
to 0mm before mastering for gun 2.

6. Once both guns are mastered, proceed to autotuning.

5.3 Autotuning

The purpose of Autotuning is to have the robot calculate certain properties of the weld gun
that are necessary for proper operation. This operation must be completed prior to pressure
calibration, tip wear setup, or any of the following sections. Autotune must be run for each servo gun
separately. It will be necessary to cycle power after running Autotune before the next gun can be
tuned. All guns should be mastered prior to Autotuning any gun.

5.3.1 Running

1. Select [3: Auto Tune] and Press [Shift] & [F3:EXEC]


• Put robot in T2 mode 100% override

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2. Select [YES] to Begin

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3. Select [OK] and continue to hold [Shift] and the Deadman

4. After Auto Tuning completes, it will be necessary to cycle power for the new parameters
to take effect.
5. Repeat above steps for all configured servo guns

5.3.2 Help and Hints

If autotuning fails there are a number of possible reasons. The following are a list of the
faults that can occur as well as some possible remedies to these faults.

1. Collision detection alarm


• The axis limits may be swapped.
• The axis limits are not set correctly.
• The gun may not be mastered correctly.
2. Stop Excess Error
• The axis limits may be swapped.

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• Gun close direction may be incorrect. Should be Plus.
• +X should close the gun, if it opens the gun then the motion sign under NoBot
setup at Controlled start needs to be changed.
• The gun may not me mastered correctly.
3. Autotune cannot start
• Verify that the robot is in T2 mode with 100% override active.
4. Pressure Shortage
• Verify Mastering
o Make sure tips are touching
• Verify Servo Gun setup at controlled start under Maintenance.

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6. Pressure calibration

Once the servo weld gun has been mastered and Auto Tuned, it is necessary to perform a
pressure calibration on the system such that the robot can determine the relationship of motor torque
to tip force. Pressure calibration will need to be carried out for each servo gun.

6.1 Equipment

To perform pressure calibration you will need the following items.

1. Calibrated Pressure Gauge set to Peak force rather than tracking.


2. Force gauge holder assembly
a. This allows for one person pressure calibration by fixing the force gauge to the
stationary gun arm so that the operator has both hands free to run the pressure
calibration from the teach pendent.
b. It is not recommended to run pressure calibration without this assembly because it is
too cumbersome to hold the force gauge and execute the pressure commands from
the teach pendent

NOTE:
Because the weld gun is an additional axis to the robot, this task must be performed with servo power
available to all robot axis.

6.2 Performing Calibration

Pressure calibration is to be performed in T1 mode at 100% override. This is possible


because the force calibration takes place at 50mm/s, which is less than 250mm/s.

The following are the steps necessary to calibrate the weld pressures on a servo gun:

1. Press [MENUS] -> [Setup] -> [Servo Gun]


2. Select <*DETAIL*> under General Setup

3. Select <*DETAIL*> under Pressure Cal: (Should show INCOMP)

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4. Select [F4:Yes] when prompted to start pressure calibration


5. Select [F4:OK] to acknowledge the torque limit note
6. Verify the following settings
• [Pressuring Time (sec)] = 2.0 These settings are for the
• [Thickness of Gauge (mm)] = 13.0 standard Sensor
• [Pushing Depth (mm)] = 8.0 Development Force Gauge
• [Gun Open Value (mm)] = 20.0

7. Verify or Add the following Pressure Targets


Verify

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Verify or Add the


following pressure
targets up to the
rated force of the
gun

8. Attach force gauge to the stationary arm of the weld gun such that the gauge face is
resting on the stationary tip.
9. Enter initial torque % for first pressure calibration test.

Enter Torque
percentage here

Start off at a low


torque to get an idea
of how the gun will
perform ~5%
starting torque

Verify
10. Verify that the speed is 50mm/s
11. With the robot servos reset press SHIFT-[F3: Pressure] to have the robot close the gun at
whatever torque was specified. (Cursor must be on the line for the requested torque)
12. Adjust Torque (%) up or down until the desired force is achieved.

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Torque can be
adjusted in 0.1%
increments

13. Repeat steps 9 - 12 for each of the pressures in the table up to the maximum rated force
of the gun. Make sure not to exceed the rated force for the gun. The motors are
stronger than the guns.

• If the necessary torque required to reach a required force exceeds the


allowed torque (Max Gun Toque (%)), it will be necessary to exit pressure
calibration by setting pressure calibration complete, and accepting/updating
the torque limits when prompted. This will update the over-torque limits. To
complete pressure calibration simply restart pressure calibration and the
limits will have been increased, allowing for the completion of pressure
calibration.

14. When torque values have been entered for all valid pressures in the table, change the
Calibration Status to complete.

Cursor up to
INCOMP when
complete with
pressure
calibration

Press F4:COMP
to complete
pressure
calibration

15. Select [F4:COMP] to enable new parameters

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16. Select [F2:END] to complete Pressure Calibration

6.3 Help and Hints

The majority of the issues that will occur during pressure calibration are errors that have to do
with the pressure calibration settings.

1. Move Error Excess


• Make sure pushing depth is set less than the gauge thickness
• Verify that Tryout mode is not active, because the robot assumes all thicknesses to
be 0mm, regardless of what is specified when in Tryout mode.
2. Stop Excess Error
• Verify that Tryout mode is not active, because the robot assumes all thicknesses to
be 0mm, regardless of what is specified when in Tryout mode.
• Verify gauge thickness
o When error occurs, select [POSN] if faulted position is -13.01 to -13.99,
change thickness to 14 mm.
3. Collision guard alarm
• Make sure that the gauge thickness is set correctly
4. Pressure gauge shows radically different pressures
• Increase Pressuring time
5. Requested Torque exceeds limit and Pressure calibration cannot be performed
• This occurs when attempting to calibrate a torque that is greater than that specified
under Max Gun Toque (%). This can occur because the values that Fanuc defaults
to are conservative and assume full mechanical advantage.
1. To allow calibration to use torques greater than max torque it is necessary to
exit pressure calibration by setting pressure calibration complete, and
accepting/updating the torque limits when prompted. This will update the
over-torque limits.
2. Restart Pressure calibration and the limits will have been increased, allowing
for the completion of pressure calibration.

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7. Thickness check calibration

Once Pressure calibration is complete it is necessary to go back to gun setup and perform
the “Thickness Check Calibration”. This allows for the gun to more accurately calculate part
thickness with the gun at force.

1. Press [MENUS] -> [Utilities] -> [TYPE] -> [Gun Setup]


2. Cursor down to item 4 ‘Thickness Check Calibration’ and press [Shift F3:EXEC] with the
dead man in and robot reset (T2 100% Override)

3. Select [YES] when prompted “Are you sure you want to do this:

4. Select [Ok] when prompted

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5. When calibration is complete, the teach pendent will indicate Complete.

6. Perform steps 1-5 for all configured servo guns.

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8. Tip Wear Compensation

Because the GM Global weld guns do not include equalizers, it is necessary to program the
stationary tip touching the metal. As the stationary tip wears through welding and tip dress, it is
necessary to determine the amount of tip wear present on each tip, and to offset the robot path to
keep the stationary tip in contact with the part throughout the life of the cap. To enable this, the robot
has certain macros that setup the tip wear compensation, and other macros that will calculate the
wear throughout the life of the cap.
There are a few things that must be remembered when running with tip wear compensation
enabled. First is that after changing the caps on the robot, it is necessary to update the tip wear,
telling the robot that it has new tips. If this is not done, the robot may bend the flange with the
stationary tip, causing damage to the part, gun, or causing collision alarms.

8.1 Setup

To setup Tip Wear Compensation it is necessary to enable compensation under Servo Gun
Setup, and to run the respective setup program for the configured servo guns. For dual guns on a
single equipment tip wear compensation is enabled or disabled for both guns

8.1.1 Enabling Tip Wear Compensation

To enable Tip Wear compensation go to the Servo Gun Setup Menu for the
respective gun and enable Tip Wear Compensation.

1. Press [MENUS] -> [Setup] -> [Servo Gun]


2. Select <*DETAIL*> under General Setup

3. [Enable] Tip Wear Down Comp

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ENABLE

Tip Wear Standard


will show COMP
when setup program
is run

Note: For dual guns Tip Wear compensation is Enabled/Disabled for both guns.

For 2 guns on 1
Equipment, Tip Wear
Comp, Gun Sag and
robot close direction
are under Dual Gun
Common

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ENABLE

8.1.2 Running Tip Wear Compensation Setup Program(s)

To run the tip wear setup program, simply select the appropriate setup program and run the
program from the teach pendent. Be sure that new caps are firmly seated on the gun before running
the tip wear setup routine.

The setup programs (macros) are as follows:

TW_SETG1.TP for Gun 1


TW_SETG2.TP for Gun 2
TW_SETG3.TP for Gun 3
TW_SETG4.TP for Gun 4

8.1.3 Wear Ratios

The wear ratio is the ratio of wear between the stationary tip and moveable tip. It is set
relative to the stationary tip. Therefore a wear ratio of .4 is 40% of total wear is relative to the
stationary tip and 60% to the moveable tip. Each gun has its own wear ratio, and they are set via
registers for ease of use. By default all ratios are set to .5, or equal wear for each tip. Based on
metal stack-up and coating they can be adjusted to better reflect the actual wear ratio.

The tip wear ratio registers are as follows:

• R[5: TW Ratio fix G1] = .5 for Gun 1


• R[6: TW Ratio fix G2] = .5 for Gun 2
• R[7: TW Ratio fix G4] = .5 for Gun 3
• R[8: TW Ratio fix G4] = .5 for Gun 4

8.2 Viewing Tip Wear values

To view the tip wear amounts :


1. Press [MENUS] -> [Setup] -> [Servo Gun]
2. Select <*DETAIL*> under General Setup

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3. Select <*DETAIL*> under Tip Wear Standrd

Shows complete when


tip wear setup has been
complete

The actual measured tip


wear will show up here.
It will show 0.00
immediately after tip
wear setup is complete.
After a wear update, or a
cap change this value
may be non zero. All
measurements are
based relative to the
setup. The values may
not be zero after a cap
change, as all caps are
slightly different in length

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8.3 Tip Wear Updating

Once tip wear setup has been completed, the robot will periodically update the tip wear value
by running a tip wear routine that will close the gun and determine the total amount of wear. It will
then apply the tip wear ratio in splitting the wear between the moveable and stationary tips. The
standard software is configured to update one gun every cycle. For a single gun case, it will update
every cycle, and for a four gun case it will update each gun every 4 cycles. There is a register in the
robot that keeps track of the last gun updated and indexes to the next gun automatically.

8.3.1 Tip Wear Routines

There are 4 different programs that are run to perform the necessary tip wear functionality.
For the most part the operator will need to do nothing with these routines as they are 'baked' into the
code, but are listed here for completeness.

TW_GUNS
This program is run whenever the steppers are reset, or whenever new cap are placed on the
robot. This routine calls TW_UPDCC(x) for every configured servo gun.

CAP_WEAR
This program is run every cycle to update the tip wear on one of the servo guns. This routine
is typically run on the way home after entering segment 63 (clear of transfer) or during a drop-off for a
pedestal application. This routine will only update a single gun every cycle because of the time
involved ~ 4 seconds. That said, each gun will update every 4 cycles worst case.

TW_UPDT(x) x= gun number


This is the routine that Cap_Wear calls to update the wear on a specific gun. This routine is
also called outright to update a specific gun by the tip dress routines. When this routine is run it will
close the selected gun and measure the tip wear from the original position that was recorded when
Tip Wear Setup was done. This routine expects that each successive measurement will show
increased wear. This routine will allow the caps to grow by a small amount (configurable) in case of a
'Cling-On' during a tip dress.

TW_UPDCC(x) x= gun number


This is the routine that TW_GUNS calls to update the wear on each gun. When this routine is
run it will close the selected gun and measure the tip wear from the original position that was
recorded when Tip Wear Setup was done. This routine expects the caps to grow, as expected with
new caps.

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9. Set Gun Close Direction

The gun close direction defines direction the tips move to close and weld. For the
moveable tip which the Fanuc software refers to as Gun, should be set to PLUS, indicating
that the positive displacement of the moveable tip closes the gun. For the Stationary tip,
which the Fanuc software refers to as Robot, needs to be set to indicate the direction that the
TCP must move to bring the stationary tip to the workpiece. This setting is critical, because it
determines the direction the robot will move to place workpiece on the stationary tip as it
goes through the motions that encompass a weld with a servo gun.

9.1 Carried +Z

For Carried spot welding applications, the gun Close direction (Robot) shall be
relative to the Utool of the gun and shall be +Z, for the tool as defined in RS-3.

9.1.1 Single Gun UT: UTOOL


Should be set to UT for
Carried Applications

1 (UTOOL #)
This is the Utool to use
for Close Gun Direction
(Robot)

+Z
The direction the robot
moves relative to the
UTOOL to bring the
stationary tip to the
metal

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9.1.2 Dual Gun Single Equipment

Select [Detail] to look at


Dual Gun Common
Items

UT: UTOOL
Should be set to UT for
Carried Applications

1 (UTOOL #)
This is the Utool to use
for Close Gun Direction
(Robot)

+Z
The direction the robot
moves relative to the
UTOOL to bring the
stationary tip to the
metal

9.2 Pedestal +Z

For Pedestal spot welding applications, the gun Close direction (Robot) shall be
relative to the UFrame of the gun and shall be -Z, for the tool as defined in RS-3.

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9.2.1 Single Gun UF: FRAME(RTCP)


Should be set to UT for
Carried Applications

1 (UFRAME #)
This is the UFrame to
use for Close Gun
Direction (Robot)

+Z
The direction the robot
moves relative to the
UFRAME to bring the
stationary tip to the
metal

9.2.2 Dual Gun Single Equipment

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Select [Detail] to look at


Dual Gun Common
Items

UF: FRAME(RTCP)
Should be set to UT for
Carried Applications

1 (UFRAME #)
This is the UFrame to
use for Close Gun
Direction (Robot)

+Z
The direction the robot
moves relative to the
UFRAME to bring the
stationary tip to the
metal

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10. Pressure schedules

General Motors has standardized on the Pressure Schedules that are to be used for all servo
welding applications. They include 2 schedules for each of the approved weld forces, with the only
difference being the part thickness set under pressure schedule detail. These 10 pressure schedules
are not to be modified, because they include the best compromise between speed, performance and
complexity. If a need arises that requires a unique pressure schedule, it will be necessary to add a
schedule. However this will require buy-in from the lead robot and welding engineers due to the fact
that it affects the weld spot verification process, and leads to uniqueness, and added complexity.

10.1 Background

The pressure schedules in the robot controls more than the weld pressures; they also
controls the way the robot approaches a weld and departs after a successful weld. There are 99
pressure schedules available for each gun. The elements listed below are available for each of the
99 schedules.

To access the pressure schedules in the robot:


1. Press [Data]
2. Press [F1: Type] -> [Pressure] 1. Setting
Manual=True will
cause the specified
Verify schedule to appear
• These are the in the select list
default pressure when the [Gun] key
schedules for all is pressed by the
robots. Only the user
forces up to the
max rated force 2. Pressing [Gun] (non-
of the gun will shifted) will select
be present the next Pressure
Schedule in the list
that is set TRUE

3. Pressing [Shift] -
[Gun] will cause the
weld gun to move to
close at the defined
pressure

10.2 Elements

There are 9 elements to each pressure schedule that need to be set correctly for the servo
guns to operate in an efficient and effective manner.

1. Weld Force
• The amount of force the gun will apply before welding.
2. Part Thickness
• The expected thickness of the part (stack up) that is to be welded.
3. Gun Sag
• The amount of deflection (flex) on the stationary tip that is caused by closing the gun
to the prescribed pressure.
4. Pushing Depth

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• The maximum distance that the robot will push to build pressure.
5. Contact Speed
• The speed at which the welding electrodes will contact the workpiece.

10.2.1 Weld Force

The weld pressure is the tip force (weld pressure) the robot will apply before initiating the
weld controller.

To access the a pressure schedule in the robot :

1. Press [Data] hard key


2. Press [F1: Type] - > [5: Pressure]
3. Cursor to select desired schedule
4. Select [F4: Detail]
5. Cursor to Weld Pressure to modify

NOTE:
Because the robot does not initiate the weld before the gun is at pressure minimal squeeze
time is necessary in the welder control.

10.2.2 Part Thickness

The part thickness must be set in order for the robot to quickly perform the weld, and can also
be used to detect that the correct / all parts to be welded are present. The part thickness needs to be
set reasonably close to the actual thickness of the part(s) to be welded because the robot uses this
thickness to determine when to switch from positional to torque mode. If this value is too large the
robot will switch to torque mode to early, and will have to search (at a slower speed) until it detects
the part. If this value is too small it is possible that the tips could touch the part while still in positional
rather than torque mode. This could lead to collision alarms, and some part deformation.

To access the a pressure schedule in the robot:

1. Press [Data] hard key


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2. Press [F1: Type] - > [5: Pressure]
3. Cursor to select desired schedule
4. Select [F4: Detail]
5. Cursor to Part Thickness to modify

Part Thickness of
3.3mm for pressure
schedule # 1

10.2.3 Gun Sag

The servo gun has the ability to compensate for gun deflection as the weld force increases,
allowing the stationary tip to remain in the same position as the force increases. This is especially
important on C-Guns where the stationary/fixed gun arm wants to deflect under load. By setting up
gun sag, the robot can move the stationary/fixed tip in the opposite direction of deflection, allowing for
a consistent weld location without the use of an equalizer. This is especially important because the
C-Guns for the GMT-966 project do not incorporate pneumatic or spring equalization, with the
exception of dual guns and hard automatic fixture guns.

10.2.3.1 Enabling

The Gun Sag Compensation must be enabled for the robot to compensate for gun deflection.

1. Press [MENUS] -> [Setup] -> [Servo Gun]


2. Select <*DETAIL*> under General Setup

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3. Select Enable under [Gun Sag Compensation]

10.2.3.2 Setup

1. Make sure that Gun Sag Compensation is enabled


2. Verify that the gun sag values are not 0.0mm in the pressure schedule detail page. [Gun
Sag Comp Value (mm)] will be calculated automatically from data taken during
Autotuning, and will be automatically filled into the pressure schedules once pressure
calibration is complete.

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This value is
calculated
automatically after
Auto Tuning and
Pressure
Calibration are
completed

10.2.4 Pushing Depth

The pushing depth indicates how far the robot will move past where it expects to build
pressure, before it faults with a pressure shortage. If the part thickness is set to 3mm, the robot
expects to build force when the tips are 3mm apart. The pushing depth feature allows the robot to
search past this point to build pressure so that minor variations in part thickness to not cause
nuisance faults. This is also useful in that we want to have a single pressure schedule for a given
force, and to have the part thickness set to the thickest of the stack-ups that are going to use that
force. Given this plan, the default pushing depth for all pressure schedules is 6mm.

To access the a pressure schedule in the robot:

1. Press [Data] hard key


2. Press [F1: Type] - > [5: Pressure]
3. Cursor to select desired schedule
4. Select [F4: Detail]
5. Cursor to pushing depth to modify

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Pushing depth is
6mm for schedules
1-16

10.2.5 Contact Speed

Contact speed indicates the speed at which the welding electrodes will contact the
workpiece. This value by default is the speed that was used during the pressure calibration of the
servo gun. This value should not be adjusted except for certain applications such as tip dress that a
higher or lower contact speed is desired for the process.

Note:
Increasing the contact speed higher than that used for calibration can lead to a higher force
deviation from that calibrated.

To access the a pressure schedule in the robot:

6. Press [Data] hard key


7. Press [F1: Type] - > [5: Pressure]
8. Cursor to select desired schedule
9. Select [F4: Detail]
10. Cursor to Contact Speed percentage to modify

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Calibrated speed for


all schedules by
default is 50mm/s

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11. Backup schedules

The robot has the ability to program backup positions that specify how much the gun is to
open when the specified Backup schedule is called. This offers a simplified method of programming
gun open positions, without requiring the user to Jog the weld gun axis. The backup command can
be added to the standard SPOT instruction, or executed as a manual function using the Backup Key.
There are 30 backup schedules that can be programmed for each gun.

To locate the Backup Data:

1. [DATA] -> [F1:TYPE] -> [6:Backup]

1. Setting Manual=True will


cause the specified gun
open distance to appear in
the select list when the
[BACKUP] key is pressed
by the user

2. Pressing [BACKUP] (non-


shifted) will select the next
Backup position in the list

3. Pressing [Shift] -
[BACKUP] will cause the
weld gun to move to the
currently selected Backup
position

The Backup Schedules are pre-defined in 10mm increments. This will allow for easy
assignment of Backup Schedules without referring to the backup data. I.e. Backup No. 1 is 10mm,
BU #2 is 20mm, BU# 15 is 150mm and so on. This table can be adjusted as necessary for specific
applications, but should be fine as is, with the operator setting Manual = True for those positions that
they want to access from the Backup Key.

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12. Distance Schedules

The robot has the ability to program distance schedules that specify how close the gun is to
be to the workpiece as it approaches a weld. The associated parameters are for Gun (Moveable)
Robot (Stationary) tips. These distance schedules are used in the SPOT instruction to determine the
position the robot moves the caps to prior to and after a weld. All values are in addition to the part
thickness. So if you are calling a SPOT instruction with a pressure schedule that is 3mm, and you
use SD(Start Distance)=4, the tips are 11mm apart. 4mm above the part, and 4mm below the part.
The same applies for ED(End Distance), which is where the robot will move the gun to after the weld.

17:L P[2] 1500mm/sec CNT100


: SPOT[SD=4,P=1,S=1,ED=4] ;

There are 99 distance schedules that can be programmed for each gun.

To locate the Backup Data:

2. [DATA] -> [F1:TYPE] -> [Distance]

The Backup Schedules are pre-defined in 1mm increments for distances 1 thru 15 This will
allow for easy assignment of Distance Schedules without referring to the distance data. I.e. Distance
1 is 1mm, Distance 10 is 10mm and so on.

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13. Program listings
13.1 Style templates

The following templates are unique to servo gun applications and are listed here so that the
differences can be explained and documented.

13.1.1 Carried Servo Gun


STPR_CHK
/PROG STYLE01 This routine checks for caps
… changed from all configured weld
1: !ECHO STYLE AND OPTION ; controllers and will perform a tip
2: GO[2:ManualStyle]=1 ; wear update automatically if the
3: ECHO OPTION ; steppers are reset. If only 1 of the
4: MAINT_PROG=MOV_REPR ; steppers on a 2 weld controller setup
5: ; are reset, the robot will prompt to
6: CALL POUNCE ; reset all steppers, or to abort the
7: ; style
8: CALL STPR_CHK ;
9: ;
10: CALL S01PROC1 ; CAP_WEAR
11: ; This routine performs a tip wear
12: RUN CAP_WEAR ; update for the gun as the robot is
13: ; moving home. Needs to be placed
14: MOVE TO HOME ; after the robot has entered segment
15: WAIT (F[1]) ; 63(clear of transfer) and is moving
/POS home
/END

WAIT (F[1]
This wait allows for the tip wear
update to complete prior to the style
aborting

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STPR_CHK
13.1.2 Single Pedestal Servo gun No Tip Dress
This routine checks for caps changed
/PROG STYLE01 from all configured weld controllers
… and will perform a tip wear update
automatically if the steppers are reset.
1: !ECHO STYLE AND OPTION ;
2: GO[2:ManualStyle]=1 ; If only 1 of the steppers on a 2 weld
3: ECHO OPTION ; controller setup are reset, the robot will
prompt to reset all steppers, or to abort
4: MAINT_PROG=FFRPROC1 ;
5: ; the style
6: ! FFR HANDLER ;
7: IF $IN_FFRCVRY=1,JMP LBL[10] ;
CAP_WEAR
8: ;
This routine performs a tip wear
9: CALL POUNCE ;
update for one gun while the robot is
10: ;
dropping the part off. (This requires
11: CALL STPR_CHK ;
that the Group masks be set correctly.
12: ;
I.e. DROPPOFF1 must not have
13: CALL PICKUP_1 ;
Group 2 Mask enabled)
14: ;
15: LBL[10] ;
For Ped applications with Tip Dress
16: CALL S01PROC1 ;
this Cap Wear is replaced with a
17: ;
Pedestal tip dress check (TD_P1_CK)
18: ! FFR HANDLER ;
that will either tip dress or do an
19: IF DO[43:FFRActive]=ON,JMP LBL[99] ;
update
20: ;
21: RUN CAP_WEAR ;
22: ;
23: CALL DROPOFF1 ; WAIT (F[1])
24: ; This wait allows for the tip wear update
25: MOVE TO HOME ; to complete prior to the style aborting
26: WAIT (F[1]) ;
27: LBL[99] ;
/POS
/END

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13.1.3 Dual Pedestal Servo Gun No Tip Dress

/PROG style01

1: !ECHO STYLE AND OPTION ;
2: GO[2:ManualStyle] = 1 ; STPR_CHK
3: ECHO OPTION ; This routine checks for caps
changed from all configured weld
4: !FFR HANDLER ;
5: IF $IN_FFRCVRY=1,JMP LBL[R[160]] ; controllers and will perform a tip
6: CALL s01pounc ; wear update automatically if the
steppers are reset. If only 1 of the
7: CALL STPR_CHK ;
8: CALL s01pick1 ; steppers on a 2 weld controller setup
9: LBL[10] ; are reset, the robot will prompt to
10: R[160]=10 ; reset all steppers, or to abort the
11: MAINT_PROG=MOV_FFRPROC1 ; style
12: CALL s01proc1 ;
13: !FFR HANDLER FOR PROCESS 1 ;
14: IF DO[43:FFRActive] = ON, JMP LBL[99] ; CAP_WEAR
15: LBL[20] ; This routine performs a tip wear
16: R[160]=20 ; update for one gun while the robot is
17: MAINT_PROG=MOV_FFRPROC2 ; dropping the part off. (This requires
18: CALL s01proc2 ; that the Group masks be set
19: !FFR HANDLER FOR PROCESS 2 ; correctly. I.e. S01DROP1 must not
20: IF DO[43:FFRActive] = ON, JMP LBL[99] ; have Group 2 Mask enabled)
21: RUN CAP_WEAR ;
22: CALL s01drop1 ; For Ped applications with Tip Dress
23: MOVE TO HOME ; this Cap Wear is replaced with a
24: WAIT (F[1]) ; Pedestal tip dress check
25: LBL[99] ; (TD_P1_CK, or TD_P2_CK) that will
/POS either tip dress or do an update
/END

WAIT (F[1])
This wait allows for the tip wear
update to complete prior to the style
aborting

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13.1.4 Single Pedestal Servo gun With Tip Dress
STPR_CHK
This routine checks for caps changed
/PROG STYLE01
from all configured weld controllers

and will perform a tip wear update
1: !ECHO STYLE AND OPTION ;
automatically if the steppers are reset.
2: GO[2:ManualStyle]=1 ;
If only 1 of the steppers on a 2 weld
3: ECHO OPTION ;
controller setup are reset, the robot will
4: MAINT_PROG=FFRPROC1 ;
prompt to reset all steppers, or to abort
5: ;
the style
6: ! FFR HANDLER ;
7: IF $IN_FFRCVRY=1,JMP LBL[10] ;
8: ;
9: CALL POUNCE ; TD_P1_CK
10: ; This routine checks to see if a tip dress
11: CALL STPR_CHK ; is necessary for the guns on Pedestal
12: ; 1 and if so will tip dress the necessary
13: CALL PICKUP_1 ; guns while the robot is dropping of the
14: ; part. (This requires that the Group
15: LBL[10] ; masks be set correctly. I.e.
15: CALL TDDMPCHK(21) DROPOFF1 must not have Group 2
16: CALL S01PROC1 ; Mask enabled)
17: ; If a tip dress is not necessary, the
18: ! FFR HANDLER ; robot will perform a cap wear update
19: IF DO[43:FFRActive]=ON,JMP LBL[99] ;
20: ;
WAIT (F[1])
21: CALL TD_P1_CK ;
This wait allows for tip wear update, or
22: ;
tip dress to complete prior to the style
23: CALL DROPOFF1 ;
aborting
24: ;
25: MOVE TO HOME ;
26: WAIT (F[1]) ;
27: LBL[99] ;
/POS
/END

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13.1.5 Dual Pedestal Servo Gun With Tip Dress STPR_CHK
This routine checks for caps changed
/PROG style01 from all configured weld controllers
… and will perform a tip wear update
1: !ECHO STYLE AND OPTION ; automatically if the steppers are reset.
2: GO[2:ManualStyle] = 1 ; If only 1 of the steppers on a 2 weld
3: ECHO OPTION ; controller setup are reset, the robot will
4: !FFR HANDLER ; prompt to reset all steppers, or to abort
5: IF $IN_FFRCVRY=1,JMP LBL[R[160]] ; the style
6: CALL s01pounc ;
7: CALL STPR_CHK ;
8: CALL s01pick1 ; TD_P1_CK
9: LBL[10] ; This routine checks to see if a tip dress
10: R[160]=10 ; is necessary for the guns on Pedestal
11: MAINT_PROG=MOV_FFRPROC1 ; 1 and if so will tip dress the necessary
12: CALL TDDMPCHK(21) guns while the robot is performing
12: CALL s01proc1 ; S01proc2. (This requires that the
13: !FFR HANDLER FOR PROCESS 1 ; Group masks be set correctly. I.e.
14: IF DO[43:FFRActive] = ON, JMP LBL[99] ; S01proc2 must not have Group 2
15: CALL TD_P1_CK ; Mask enabled). This allows the robot
16: LBL[20] ; to tip dress the guns on pedestal 1
17: R[160]=20 ; (Fanuc Equipment 1, Nobot group 2)
18: MAINT_PROG=MOV_FFRPROC2 ; while welding with Pedestal 2 (Fanuc
12: CALL TDDMPCHK(24) Equipment 2, NoBot group 3)
19: CALL s01proc2 ; If no tip dress is necessary, the robot
20: !FFR HANDLER FOR PROCESS 2 ; will not perform a cap wear, that will be
21: IF DO[43:FFRActive] = ON, JMP LBL[99] ; done in TD_P2_CK. In this case the
22: CALL TD_P2_CK ; Run Cap Wear needs to be removed
23: CALL s01drop1 ; from TD_P1_ck
24: MOVE TO HOME ;
25: WAIT (F[1]) ;
26: LBL[99] ;
/POS
TD_P2_CK
/END
This routine checks to see if a tip dress
is necessary for the guns on Pedestal
2 and if so will tip dress the necessary
guns while the robot is dropping of the
part. (This requires that the Group
masks be set correctly. I.e. S01drop1
must not have Group 2 or 3 Mask
enabled)
If a tip dress is not necessary, the
robot will perform a cap wear update

WAIT (F[1])
This wait allows for tip wear update, or
tip dress to complete prior to the style
aborting

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13.2 Miscellaneous Servo Gun Macros

13.2.1 Stepper Check

This routine is called at pounce by all servo gun applications. It checks if the Steppers are
reset, and if so performs a tip wear update automatically. This is critical if the steppers were reset
from the DEP, or through some means that did not do a tip wear update. This routine does not check
if an update was done, but simply performs an update on all configured Servo Guns. This routine will
also check that all configured steppers are reset and prompt the user to reset all or abort if it detects
only one of two steppers reset. This is because it is critical for dual guns on one equipment that they
are capped out together, because of the tip wear compensation and the lack of equalizers.

/PROG STPR_CHK

1: !******************************** ;
2: !THIS MACRO RUNS TIP WEAR UPDATE ;
3: !IF IT DETECTS THAT STEPPERS ARE ;
4: !RESET ;
5: !IT CHECKS FOR ALL CONFIGURED SCR ;
6: !******************************** ;
7: ;
8: IF $SPOTCONFIG.$NUM_WD_CTLS=1,JMP LBL[10] ;
9: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[10] ;
10: JMP LBL[20] ;
11: ;
12: LBL[10] ;
13: IF DI[205:diSW1StepReset]=ON,JMP LBL[40] ;
14: JMP LBL[99] ;
15: ;
16: LBL[20] ;
17: IF DI[205:diSW1StepReset]=ON AND DI[221:diSW2StepReset]=ON,
: JMP LBL[40] ;
18: IF DI[205:diSW1StepReset]=ON AND DI[221:diSW2StepReset]=OFF,
: JMP LBL[30] ;
19: IF DI[205:diSW1StepReset]=OFF AND DI[221:diSW2StepReset]=ON,
: JMP LBL[30] ;
20: JMP LBL[99] ;
21: ;
BOTH STEPPERS ARE NOT RESET
22: LBL[30] ;
VERIFY THAT ALL CAPS CHANGED
23: !******************************** ;
SELECT:
24: !PROMT USER FOR DIRECTION ;
(YES) TO RESET ALL STEPPERS
25: !IF ALL CONFIGURED STEPPERS ARE ;
(NO) TO ABORT STYLE
26: !NOT RESET ;
27: !******************************** ;
28: ;
29: DO[48:Process1Fault]=ON ;
30: CALL PROMPTYN(3,40) ;
31: ;
32: DO[48:Process1Fault]=OFF ;
33: IF R[40:PROMPT Y/N REG]=1,CALL TIP_RST ;
34: IF R[40:PROMPT Y/N REG]=0,CALL ABORTIT ;
35: JMP LBL[99] ;
36: ;
37: LBL[40] ;
38: !If Air gun skip tip wear update ;
39: IF $sgcfg[1].$EQUIP_TYPE=1,JMP LBL[99] ;
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40: CALL TW_GUNS ;
41: ;
42: LBL[99] ;
43: ;
/POS
/END

13.2.2 CAP_WEAR

This routine is called either by the style program or by the tip dress check program for
pedestal tip dressing robots. For carried guns this routine should be called after the robot is clear of
transfer (Segment 63) and on the way home. For pedestal applications this routine should be called
before the drop off routine, so that the robot can update a gun while dropping the part off. This
routine calls NUM_GUNS which determines the number of servo guns on the robot. It then
increments a R15 by 1 and does a wear update on that gun. Once the number of guns limit is
reached it sets R15 to 0 and the updating starts back at gun 1. The semaphore allows this task to
compete prior to aborting the style program. See style templates for examples

/PROG CAP_WEAR

1: F[1] = (OFF) ;
2: IF $SPOTCONFIG.$STROKE_ENBL=0,JMP LBL[99] ;
3: CALL NUM_GUNS ;
4: R[15]=R[15]+1 ;
5: IF R[15]>R[16],JMP LBL[10] ;
6: CALL TW_UPD(R[15]) ;
7: JMP LBL[20] ;
8: LBL[10] ;
9: R[15]=0 ;
10: LBL[20] ;
11: IF R[15]=R[16],JMP LBL[10] ;
12: LBL[99] ;
13: WAIT (F[1]) ;
/POS
/END

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13.2.3 Number of Guns

This routine is called by CAP_WEAR and simply determines the number of servo guns active
on the robot. It puts this value in R16.

/PROG NUM_GUNS

1: ;
2: !GUN 1 IS EQ1 GUN 1 ;
3: R[16:NUM SERVO GUNS]=1 ;
4: IF $spoteqsetup[1].$num_guns=1,JMP LBL[30] ;
5: !GUN 2 IS EQ1 GUN 2 ;
6: R[16:NUM SERVO GUNS]=2 ;
7: LBL[30:END EQ1 CHECK] ;
8: ;
9: IF $SPOTNUMEQ=1,JMP LBL[99] ;
10: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[99] ;
11: ;
12: IF $spoteqsetup[1].$num_guns=2,JMP LBL[40] ;
13: !GUN 2 IS EQ2 GUN 1 ;
14: R[16:NUM SERVO GUNS]=2 ;
15: JMP LBL[50] ;
16: ;
17: LBL[40: RESET GUN 3] ;
18: !GUN 3 IS EQ2 GUN 1 ;
19: R[16:NUM SERVO GUNS]=3 ;
20: ;
21: LBL[50: RESET GUN 4] ;
22: IF $spoteqsetup[2].$num_guns=1,JMP LBL[99] ;
23: !GUN 4 IS EQ2 GUN 2 ;
24: R[16:NUM SERVO GUNS]=4 ;
25: ;
26: LBL[99] ;
/POS
/END

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13.2.4 TW_GUNS

This routine is called by TIP_RST, after a cap change to run a tip wear update on all configured servo
gun. TW_UPDCC(X) is the tip wear program for new caps (Tip Wear Update Caps Changed),
where X is the gun number. This routine also makes sure that stroke is enabled, so the robot does
not try to update in no stroke.

/PROG TW_GUNS

1: IF $SPOTCONFIG.$STROKE_ENBL=0,JMP LBL[99] ;
2: !If Air gun skip tip wear update ;
3: IF $sgcfg[1].$EQUIP_TYPE=1,JMP LBL[99] ;
4: !GUN 1 IS EQ1 GUN 1 ;
5: CALL TW_UPDCC(1) ;
6: IF $spoteqsetup[1].$num_guns=1,JMP LBL[30] ;
7: !GUN 2 IS EQ1 GUN 2 ;
8: WAIT .30(sec) ;
9: CALL TW_UPDCC(2) ;
10: LBL[30:END EQ1 CHECK] ;
11: ;
12: IF $SPOTNUMEQ=1,JMP LBL[99] ;
13: ;
14: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[99] ;
15: !If Air gun skip tip wear update ;
16: IF $sgcfg[2].$EQUIP_TYPE=1,JMP LBL[99] ;
17: IF $spoteqsetup[1].$num_guns=2,JMP LBL[40] ;
18: !GUN 2 IS EQ2 GUN 1 ;
19: WAIT .30(sec) ;
20: CALL TW_UPDCC(2) ;
21: JMP LBL[50] ;
22: ;
23: LBL[40: RESET GUN 3] ;
24: !GUN 3 IS EQ2 GUN 1 ;
25: WAIT .30(sec) ;
26: CALL TW_UPDCC(3) ;
27: ;
28: LBL[50: RESET GUN 4] ;
29: IF $spoteqsetup[2].$num_guns=1,JMP LBL[99] ;
30: !GUN 4 IS EQ2 GUN 2 ;
31: WAIT .30(sec) ;
32: CALL TW_UPDCC(4) ;
33: ;
34: LBL[99] ;
/POS
/END

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13.2.5 Tip Reset

This routine gets called to reset steppers. This can occur either at a 'Request Continue' with
a decision code 14, or as a style 27 'Cap Change'. This routine checks that the watersavers have
detected a 'Cap Loss' or are bypassed before allowing the steppers to be reset. If it detects that the
configured watersaves are not tripped, or bypassed it will prompt the user to 1. Reset anyway, or 2.
Skip Reset. If the watersavers were tripped, or the operator selected reset anyway, the robot will
then reset all configured steppers and watersavers, and will then perform a TW_GUNS which will
update the wear for all servo guns.

/PROG TIP_RST

1: !******************************** ;
2: !TIP RESET WELD CNTRLS ;
3: !THIS MACRO RESETS STEPPERS ;
4: !FOR ALL CONFIGURED SCRS ;
5: !IF CAP LOSS OR BYPASS DETECTED ;
6: !******************************** ;
7: ;
8: ;
9: IF $SPOTCONFIG.$NUM_WD_CTLS=1,JMP LBL[10] ;
10: IF DI[309:diG1WS_CapLoss]=ON AND DI[317:diG2WS_CapLoss]=ON,
: JMP LBL[20] ;
11: IF DI[307:diG1WS_Bypassed]=ON AND DI[315:diG2WS_Bypassed]=ON,
: JMP LBL[20] ;
12: IF DI[309:diG1WS_CapLoss]=ON AND DI[315:diG2WS_Bypassed]=ON,
: JMP LBL[20] ;
13: IF DI[307:diG1WS_Bypassed]=ON AND DI[317:diG2WS_CapLoss]=ON,
: JMP LBL[20] ;
14: JMP LBL[30] ;
15: ;
16: LBL[10] ;
17: IF DI[309:diG1WS_CapLoss]=ON,JMP LBL[20] ;
18: IF DI[307:diG1WS_Bypassed]=ON,JMP LBL[20] ;
19: JMP LBL[30] ;
20: ;
21: LBL[20] ;
22: !RESET STEPPER AND WATER SAVER ;
23: !FOR WELD CONTROLLER 1 ;
24: ;
25: CALL RST_STP1 ;
26: CALL RST_WTR1 ;
27: ;
28: IF $SPOTCONFIG.$NUM_WD_CTLS=1,JMP LBL[40] ;
29: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[40] ;
30: !RESET STEPPER AND WATER SAVER ;
31: !FOR WELD CONTROLLER 2 ;
32: ;
33: CALL RST_STP2 ;
34: CALL RST_WTR2 ;
35: ;
36: JMP LBL[40] ;
37: ;
38: LBL[30] ;
39: !******************************** ;
40: !PROMT USER TO RESET ANYWAY IF ;
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41: !WATERSAVERS DID NOT TRIP ;
42: !OR WERE NOT BYPASSED ;
43: !******************************** ; WATERSAVERS NOT TRIPPED
44: ; ARE ALL CAPS CHANGED?
45: DO[48:Process1Fault]=ON ; SELECT:
46: CALL PROMPTYN(2,40) ; (YES) TO RESET STEPPERS
47: ; (NO) TO SKIP STEPPER RESET
48: DO[48:Process1Fault]=OFF ;
49: IF R[40:PROMPT Y/N REG]=1,JMP LBL[20] ;
50: IF R[40:PROMPT Y/N REG]=0,JMP LBL[99] ;
51: ;
52: LBL[40] ;
53: !If Air gun skip tip wear update ;
54: IF $sgcfg[1].$EQUIP_TYPE=1,JMP LBL[99] ;
55: CALL TW_GUNS ;
56: ;
57: LBL[99] ;
58: ;
/POS
/END

13.2.6 Cap Select

This routine is called at FFR to allow the user to select that the caps were changed, so that
the robot can reset the steppers and perform a tip wear update before returning to the style to re-weld
the part.

/PROG CAP_SELC

1: !******************************** ;
2: !THIS MACRO ALLOWS THE USER TO ;
3: !SELECT IF THE CAPS WERE CHANGED ; HAVE THE CAPS BEEN CHANGED?
4: !AT FFR ; (ALL CAPS MUST BE CHANGED)
5: !STEPPERS ARE RESET IF USER ; SELECT:
6: !ANSWERS YES TO THE PROMPT ; (YES) TO RESET STEPPERS
7: !******************************** ; (NO) TO CONTINUE W/ OLD CAPS
8: ;
9: !******************************** ;
10: !PROMT USER FOR DIRECTION ;
11: !IF CAPS CHANGES AT FFR ;
12: !******************************** ;
13: ;
14: CALL PROMPTYN(4,40) ;
15: ;
16: IF R[40:PROMPT Y/N REG]=1,CALL TIP_RST ;
17: ;
18: LBL[99] ;
19: CALL USERCLR ;
20: CALL USERPAGE ;
/POS
/END

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14. Recovery

The following are the recommended recovery procedures necessary to recover from the
most common and foreseeable errors that will occur once the servo guns are in production. It is
anticipated that this section will grow as we garner more information and additional lessons learned.

14.1 Recovery from Loss of Mastering

The steps outlined below are necessary to recover from a loss of mastering, after the robot
has been setup and programmed. It is recommended that the caps not be changed before the
following procedure, as the wear in the caps are accounted for in the recalibrate routine.

14.1.1 Mastering the Gun from the Master/Calibrate screen

This method is to be used to recover from a loss of mastering after initial setup of the servo
gun has been performed.

1. Do not replace the electrodes


• The robot will use the existing cap wear to calculate correct position and update
the tip wear automatically
2. Press [MENUS] -> [NEXT PAGE] -> [SYSTEM] -> [Gun Master]
3. Select [Select F3:BZAL] to reset the battery zero alarm and cycle power

4. Re-Establish pulse with the encoder


5. Select [NEXT]
6. Jog the welding electrodes (tips) together until they just touch
7. Select [F4:RECALB]
• This will master and calibrate the gun, and update the tip wear compensation
master position

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8. The axis is now mastered


9. Verify the weld path, and touch up if necessary

14.2 Cap configuration change

The steps outlined below are necessary to change from one cap configuration to another due
to product or process changes. This includes the change of cap size, say from a #2 short to a #2
long, or change from one shank style to another. It is not recommended to single axis master and
update limits on this axis, as this tends not to work, and can cause issues with tip wear.

14.2.1 Re-Run the wizard

To ensure that the transition from the original cap configuration to the new configuration is
successful, and straight forward it is necessary to delete the gun axis in question from the group, and
to re-enter the axis with the new information, paying close attention to the axis limits. The easiest
way to accomplish this is to re-run the wizard and to select YES when prompted to setup the servo
gun axis.

14.2.2 Mastering the Gun and Setting Axis Limits

Because the axis information has been updated it is necessary to re-run the gun mastering
and axis setup.

See section Mastering the Gun to re-master the gun

14.2.3 Running Tip Wear Setup

Because the mastering information has changed, particularly the master counts with the new
caps, it will be necessary to re-run tip wear setup.

See section Tip Wear Compensation to setup tip wear compensation. It may also be
necessary to update the wear ratio when changing cap configurations.

14.2.4 Completing Pressure Calibration

Because the gun setup has changed pressure calibration has changed and should be
verified. Most likely the torque to force curve has not changed due to a simple cap change, but
should be verified. The values that were recorded during the initial setup of the pressure table are
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still in the robot, and all that should be necessary is to select complete on pressure schedule setup.
There is no need to go and setup the pressure schedules again, only to verify the calibration.

See section Pressure calibration for information concerning pressure calibration.

14.2.5 Path Touch up

Because the tip configuration has been changed it will be necessary to touch up the path.

14.3 Motor Replacement

The steps necessary to recover from a motor replacement are nearly identical to those
outlined in Recovery from Loss of Mastering, with the added steps that Autotune needs to be run as
outlined in Autotuning, and pressure calibration needs to be re-run as outlined in Pressure calibration.
It should not be necessary to run Autotuning again

Steps to recover from motor replacement:

1. Replace Motor
2. Re-master the gun
3. Re-run Autotune for the specific gun
4. Re-Run Pressure Calibration

Note: This assumes that the replacement motor type is the same make and model.

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15. Variable Listing

The following are variables that relate to servo guns.

$SGSYSCFG

$pst_ertype: Pressure Shortage Error type


0 = The pressure shortage error is posted as a warning (programs do not pause )
1 = The pressure shortage error is posted as a pause error.

$allow_stdsp: Display Standalone Spot instruction


FALSE = Editor does not display standalone spot instruction
TRUE = Editor will display standalone spot instruction

$rel_press: Release pressure at program pause


0 : Keep pressure at paused
1 : Release pressure at paused

$prs_units: Pressure units


This variable indicates how pressure data is displayed (and entered).
The internal representation and stored values are in kgf.
1 = lbf
2 = Newton
0,other kgf ( default )

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Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
Customization
16. Common Errors on Servo Gun Errors

16.1 SRVO-023: SERVO Stop error excess (G:%d A:%d)

Cause: When the servo stopped, the position error was abnormally large.
Remedy:
1. Check the ARM1 cable for connectivity, and that no bent pins exist.
2. Check voltage on ARM1 cable (approx100-300Vac when commanded to move).
3. Check that gear ratio is set correctly and matches gun tag. Press Menu’s then Type
select Autotune the value will under Tip Displacement.
4. If a disconnection is not found, replace the servo amplifier or the servo motor.

16.2 SRVO-024: SERVO Move error excess (G:%d A:%d)

Remedy: Take the same action as for SRVO–023

16.3 SRVO-069: SERVO CRCERR alarm (Grp:%d Ax:%d)

Cause: The serial data has been disturbed during communication.


Remedy:
1. Check for loose connection on the ARP1 cable. Then reboot robot.
2. Check cable routing (isolate cable from 480v cables and RM1 robot cable) to reduce
interference.
3. Check for water intrusion in ARP1 connector at servo motor and inside servo gun end
cap. Common for vertical mounted ped guns where bushing is facing upward.
4. Replace servo gun motor.

16.4 SRVO-062: SERVO BZAL alarm (Group:%d Axis:%d)

Cause: This alarm is issued when the battery for backing up the absolute position data of the
pulse coder is not connected. The battery cable inside the robot might have become
disconnected.
Remedy: Correct the cause of the alarm, by pressing MENU’S then SYSTEM select GUN
MASTER press F3 and reboot robot. Mastering will need to be performed at this
point.

16.5 SRVO-068: SERVO DTERR alarm (Grp:%d Ax:%d)

Cause: The serial pulse coder did not return serial data in response to a request signal.
Remedy:
1. Make sure that the ARP1 connector on the servo gun is securely connected and check
for bent pins.
2. Check that the shielding of the robot interconnection cable (for the pulse coder) and
check that cable is not run with 480v cables.
3. Replace the robot ARP1 cable (for the pulse coder).
4. Replace the pulse coder.

16.6 SVGN-023: Incomplete Pressure calibration

Cause: Incomplete pressure calibration.


Remedy:
1. Go to the Servo Gun Setup: General Setup Page.
2. Select Pressure Cal. and complete the Pressure Calibration process.

57
General Motors Corporation. All Rights Reserved.
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Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
Customization
16.7 SVGN-024: Incomplete Wear Down calibration

Cause: Incomplete Wear Down calibration.


Remedy:
1. Change Caps with New Caps.
2. Check Zero Position of the Servo Gun and Master if necessary.
3. Run TW_SETG1

16.8 SVGN-032: Tip increased error

Cause: The tip wear down value exceeds the increased error.
Remedy:
1. Check to ensure the CORRECT Weld Tips are on the Weld Gun.
2. If the Weld Tips are not correct, change them, and run Cap_chng/Reset Steppers.
3. If the Weld Tips are correct, run Capwear and verify the gun is closing completely during
the Capwear routine.
4. If the Servo Gun Does not close completely while running Capwear, apply lubricant to the
shaft, exercise the Servo Gun and retry Step 3.
5. If the Servo Gun still does not close the gun may need to be recalibrated (Auto
Tuned/Pressure Cal). Pay close attention to the Gun Impedance Value before and after
Auto Tuning. If the Gun Impedance Value increased significantly, the Servo Gun may
have a bind or the Servo Motor may need to be replaced.
6. If a bind is suspected on a C-Type Weld Gun, check the Guide Rod (Slide on Global) on
the Movable Side for straightness, wear and heat. Repair/Replace Guide Rod and re-run
Step 5.
7. If the Servo Motor seems excessively noisy or the shaft of the motor is excessively
warm/hot, remove the Servo Motor. If the Servo Motor is Noisy, replace the Motor.
Inspect the Bushing (Slide on Global) for weld debris, which may cause the increased
Gun Impedance.

16.9 SVGN-118: Max wear exceeded

Cause: The maximum tip wear amount has been exceeded.


Remedy:
1. Inspect weld tips for excessive heat and abnormal wear, and inspect weld gun arms for
cracks.
2. If Weld Tips appear normal replace and run Cap_Chng/reset steppers.
3. If there appears to be excessive heat on the weld tips, check for adequate water flow and
check the water tube inside the weld shank.
4. If there appears to be abnormal wear, check the tip dress path, weld pressure at tip
dress, and the tip dress cutter.
5. If weld gun arm is cracked, replace gun arm, check servo gun mastering, and verify all
process/tipdress paths.

16.10 SVGN-020: Pressure shortage

Cause: Actual pressure is less than the requested pressure.


Remedy:
1. Check mastering of tips.
2. Check tip wear if questionable install new caps and run TW_SETG1.
3. If problem still exist check part thickness and pushing depth settings in the pressure
schedule.
4. If this fault only occurs during CAPWEAR then the gun impedance has changed therefore
auto tuning and pressure calibration are required. The gun needs to be inspected to find
the cause of the impedance change, common issues are weld slag buildup in bushing,
improperly installed bushing, and bent guide rod, (c-gun slide in global applications) If
58
General Motors Corporation. All Rights Reserved.
-UNCONTROLLED WHEN PRINTED-
Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4
Customization
any of the above issues are present-correct the issue and perform auto-tune and
pressure calibration before resuming use of the gun.

Note: Always check gun impedance before and after when any mechanical maintenance is
performed on the servo gun to see how it affected the characteristics of the gun.

16.11 How to check gun impedance:

1. Press Menus key


2. Select Setup then hit ENTER
3. Press Type[F1]
4. Select Servo gun
5. Cursor down to 2nd line (General Setup) then hit ENTER
6. Cursor down to Overtorque Protection then hit ENTER
7. Press OK
8. Select Parameter Summary then ENTER
9. Verify item 1 (Display Units) is in TorqCt if not Select F4 to change
10. Gun Impedance is displayed in the row stating “Std. Overtorque Value”.

59
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