Programming training

Welding
 Foreword
This Training Booklet for programming training is a short-form extract from various Operation Manuals
of the YASNAC DX100/ FS100 / DX200 Controller. It describes a simplified form of handling and operat-
ing the controller.
The training document was created on the basis of the training contents and training processes and is
designed for use as an accompanying working document during the training. The booklet is based on
he training booklet of the user training and does not contain contents of the user training.
We do not accept any responsibility for the correctness of this information. In case of doubt, please refer
to the respective Operation Manual for assistance. Please read all the instructions and texts of this
Training Booklet carefully and proceed to take action only after you have understood the contents.
Should ambiguities arise, please refer to the respective Operation Manual or ask an employee of YAS-
KAWA Europe GmbH.
For the sake of product improvements, YASKAWA reserves the right to modify the controller without pri-
or notice. Modifications will be included in a future edition of the Training Booklet. This Training Booklet
will only serve its intended purpose if the display indicator in the manufacturer's standard is used with
menu symbols without Multi-Window and labels. The proper use of this booklet may be compromised in
case of customized menu navigation and labeling of data and data fields.

Copyright Information
All training and information documents and the contents thereof handed out during training and ceded
for use are protected by copyright. These documents and extracts thereof must not be copied, present-
ed, lent or sold. The software used during training and the files created with it as well as the documents
that are handed out are the property of YASKAWA Europe GmbH as the holder of rights and must not
be copied, presented, lent or sold. In case of non-observance we reserve the right to take action under
civil and criminal law and prohibit the concerned persons to take part in the training.
The intellectual property is protected by various rights - such as patent right, trademark right and copy-
right - of YASKAWA Europe GmbH.

Version 3
Version: February 2015

Editorial:
YASKAWA academy
Author: Trainers of YASKAWA academy
[email protected]

Production/Print
ADVOPLUS & LAMMERT
www.advoplus.de

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1 Setting the teach conditions ............................................................................ 4
2 The Tool ............................................................................................................. 5
3 Tool Coordinate System................................................................................. 11
4 Defining User Coordinates............................................................................. 14
5 Signals (Inputs/Outputs) ................................................................................ 18
6 Linking of Jobs (JUMP/CALL)........................................................................ 23
7 Variable ............................................................................................................ 29
8 Inform list......................................................................................................... 35
9 CUBE Space Overlap ...................................................................................... 36
10 Synchronous Programming (SMOV) ............................................................. 42
11 Weaving ........................................................................................................... 44

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3
1 Setting the teach conditions

In programming mode, various aspects can be set under "Setup" (without parameter
changes).

1.1 Calling up the teach conditions

1.2 Meaning of the settings

Designation Parameter Selection Meaning

Instruction set =0 BASIS Available instructions in the
S2C 211 =1 STANDARD INFORMLIST
=2 ADVANCED
Remember instruction input S2C 214 =0 INVALID Retaining of instruction val-
=1 VALID ues in the message line
Save MOVE instruction after S2C 206 =0 LINE Insert under cursor or after
=1 STEP next MOV
Beep when teaching positions S2C 433 =0 CHECK With or without beep
=1 WITHOUT
CHECK
Change only steps S2C 203 =0 ALLOW
=1 LOCK
Coord. rectangular/cylindrical S2C 196 =0 RECTANG. Robot coordinates
=1 CYLINDR.
or
Change tool (64 TCP´s) S2C 431 =0 ALLOW 1 or 64 tools
=1 LOCK
Tool no. not overwrite S2C 234 =0 ALLOW Write protection of tool
=1 LOCK number during reteaching
On or Off
Reteach only moved axis groups S2C 320=0 ALLOW
=1 LOCK
Restore deleted JOBs S2C 413=0 INVALID Activate trash for deleted
=1 VALID jobs
Job/Test run mode S2C 231=0 SIMPLE
=1 ALL
BWD-step witout axis group S2C 688 =bit ALLOW
LOCK
BWD- step in the parallel job S2C 688 =bit ALLOW
LOCK
Double coordinates S2C 434=0 INVALID
=1 VALID SHIFT
7SYNCRO
SINGLE
+

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2 The Tool

2.1 TCP measuring

It is possible to use up to 64 tool files.
Depending on the setting in the "TEACH CONDITIONS" or in the parameters, 1 or 64
tool file(s) is/are provided.

Tool
File 0
User coordinate file 1
User coordinate file 2
User coordinate file 3
Tool
File 63

2.2 Call of a tool file

SELECT

Bild 1: Overview for 64 tools (left) and tool file e.g.tool 0 of 64 tools (right)

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 2.3 Dimensions in the tool file

260 mm 260 mm 260 mm

TCP TCP TCP

ZF 145 mm
ZF
Tool A Tool B Tool C

2.4 Manual tool entry

With a calibrated robot and no tool dimensions entered, the
TCP is always centred on the underside of the flange. De-
pending on the tool, the difference from the flange centre to
the tool control point has to be entered in the respective co-
ordinate axis.
If no tool angles (Rx; Ry; Rz) have been entered, the posi-
tive direction of the Z axis always points outward from the
flange.

The tool dimensions in X; Y; Z are entered via the numerical keypad of the PP.
The entered values are accepted into the file with ENTER.

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E180000005GB03 7
 2.5 Measuring the tool with the robot (TCP measurement)

In multi-robot installations, the axis group (R1, R2,...R8) must be selected.

Move to and save 5 robot positions (named TC1 to TC5) to a fixed position (most suit-
ably a tip) with different axis positions of all robot axes.
The positions are saved with MODIFY + ENTER .

6% 6%

6%
6%
6%

After all 5 points have been saved, the tool calibration must be terminated with
.

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E180000005GB03 9
 2.5.1 Representation of the 5 positions for the TCP measurement
The positions should be considered reference points.

Position TC1

Position TC2 Position TC3

Position TC4 Position TC5

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3 Tool Coordinate System

3.1 Setting up tool coordinates

In order to set up the tool coordinate system, the tool angles must be entered into the
tool file or measured. (path to tool file see “Call of a tool file” on page 5).

3.2 Manual entry of tool angles

The tool coordinate system hat its origin always in the TCP. The orientation of the Z
axis is always in the direction of thrust of the flange. After a TCP measurement, the or-
igin, the tool coordinate system, is shifted accordingly.
The tool angles are rotated as in the following example:

No entries yet = TCP on flange

Entries in X and Z = TCP at the torch

tip.
The tool coordinate system is shifted
in parallel.

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 Rotation about X axis Rotation about Y axis

Rotate by X 180 degrees

Rotate by Y - 45 degrees

The angle is entered at Rx here The angle of rotation is entered at Ry here

It makes sense with the tool coordinate system to match the axis coordinates to the ro-
bot coordinate system. With an upright robot, the positive Z direction is "up, away from
the component", so that the positive Z direction of the tool coordinates should also be
set as "away from the component".

CAUTION
When using a Q-Set, tool coordinates should not be used.
DANGER OF CRASHING

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E180000005GB03 13
4 Defining User Coordinates

It is possible to use up to 63 user coordinate files.

User coordinate
File 1
User coordinate file 2
User coordinate file 3
User coordinate file 4
User coordinate
File 63

4.1 Definition of the user coordinate system

Displayed in the controller as USER FRAME (#UF).

Z- axis

X-axis
XX
XY
Y-axis
ORG

Definition points of the user coordinates

Item Definition Meaning

ORG Initial point Defines the origin of the coordinate system.

XX Point on the X axis Defines the orientation of the X axis with respect to the
ORG.

XY Point in the XY plane Defines in which plane perpendicular to the defined X axis
the Y axis and the Z axis are defined.

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E180000005GB03 15
 4.2 Calling up the user coordinate file

Select the desired user file with SELECT.

According to the position to be saved (ORG, XX or XY), select this in the selection
menu.
The positions are saved with MODIFY + ENTER .
After all 3 positions have been saved, the setup of the
user coordinate system must be terminated and completed.

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4.3 Selecting the user coordinate system
To select one of the 63 user coordinate systems manually, the symbol of the user co-
ordinate system in the status area must be selected first.

The selection list for the user coordinates can then be opened with

TOOL SEL

SHIFT + COORD .

The desired number becomes active when cursor is placed on it and is directly dis-
played in the symbol in the status area.

TOOL SEL
Use SHIFT + COORD to exit from the selection menu.

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5 Signals (Inputs/Outputs)

5.1 Signals of the controller

Inputs are signals that lead to the controller.
Outputs are signals that are set from the controller.
Standard of a controller without extension cards.

Standard
Inputs /outputs
inputs /outputs expandable to ...
up to 2048 signals
each 40 signals

24 universal Distribution depends on

inputs /outputs the use and application
cards.
16 special See the system's
inputs /outputs documentation site.

Signal name Number/Bits Shortcut

Universal input 1 IN#(12)

Universal output 1 OT#(5)

Half universal input group 4 IGH#(2)

Half universal output group 4 OGH#(1)

Universal input group 8 IG#(1)

Universal output group 8 OG#(3)

Special input 1 SIN#(17)

Special output 1 SOUT#(57)

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E180000005GB03 19
 5.2 Binary coding for half groups and groups

Maximum Signal partitioning Designations

possible

IG#(256) IG#(1) Input groups

IGH#(512) IGH#(2) IGH#(1) Half input groups

IN#(2048) Single inputs

IN#(8)

IN#(7)

IN#(6)

IN#(5)

IN#(4)

IN#(3)

IN#(2)

IN#(1)
OG#(256) OG#(1) Output groups

OGH#(512) OGH#(2) OGH#(1) Half output groups

OT#(2048) Single outputs

OT#(8)

OT#(7)

OT#(6)

OT#(5)

OT#(4)

OT#(3)

OT#(2)

OT#(1)
8 7 6 5 4 3 2 1 Signal number

27 to 20 27 26 25 24 23 22 21 20 Binary code group

128 64 32 16 8 4 2 1 Decimal value

Result Examples for the group

0 0 0 0 0 0 0 0 0 All 8 off

1 0 0 0 0 0 0 0 1 Only the first on

3 0 0 0 0 0 0 1 1 First and second on

7 0 0 0 0 0 1 1 1 First, second and third on

21 0 0 0 1 0 1 0 1 First, third and fifth on

255 1 1 1 1 1 1 1 1 All 8 on

Examples for the half group

23 22 21 20 23 22 21 20

8 4 2 1 8 4 2 1

0 0 0 0 0 All 4 off

1 0 0 0 1 Only the first on

2 0 0 1 0 Only the second on

3 0 0 1 1 First and second on

5 0 1 0 1 First and third on

15 1 1 1 1 All 4 on

0 = Signal Off

1 = Signal On

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5.3 Displaying the status of I/O signals
All signals can be displayed in their current state. Output signals can be switched
manually, and input signals can be simulated.

Universal inputs Universal outputs

Simulate inputs Switch outputs

Place the cursor on the field Place the cursor on the circle

INTER
Switch with SELECT Switch with
LOCK
and SELECT

Input is in simulation mode Output is switched ON

INTER
Switch input with and SELECT
LOCK

Input in simulation mode is ON

If a simulation has been activated, the execution

must be released by means of a safety request.

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 5.4 Signal instructions

5.4.1 Calling up signals

Instructions for the programming of signals are called up via the Informlist.

DOUT AOUT

INFORM IN / OUT
DIN
WAIT
ARATION
ARATIOF
LIST PULSE

The instructions are selected with SELECT and can be directly edited in the instruction
line or in the corresponding DETAIL VIEW.

5.4.2 Instruction examples with explanations

Instructions Meaning

DOUT OT#(1) ON
Switches output 1 On

DOUT OGH#(1) 15
Switches output 1, 2, 3 and 4 On

DOUT OG#(2) 76
Switches output 11,12 and 15 On

DIN B000 SOUT#(59) Saves the status of Special output 59 in variable B000 (1 = ON / 0 =
OFF)

DIN B010 OG#(2) Saves the status of the output group 2 in variable B010 (e.g. output 11,
12, 15 = On with B010 = 76)

WAIT IN#(33) ON
Wait until input 33 is On

WAIT IG#(1) 255

Wait until input 1, 2, 3, 4, 5, 6, 7 and 8 is On

PULSE OT#(38) T=1.50

Switch output 38 on for 1.5 seconds

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6 Linking of Jobs (JUMP/CALL)

JUMP and CALL are control instructions. They serve e.g. to change between two
jobs. A prerequisite is that the jobs are of the same job type (e.g.: robot job > robot job
or parallel job > parallel job).
It must also be observed that the axis group of the jobs is not different.
(e.g.:) R1 > R1 or R1+S1:S1 > R1+S1:S1 or no axis group > R1).

6.1 JUMP 6.2 CALL

When JUMP is used, the active job changes to When CALL is used, active job changes to the
the linked job and terminates there. linked job and at the end automatically returns to
the calling job under the calling instruction.

JOB: AB JOB: XY JOB: AB JOB: XY

0000 NOP 0000 NOP 0000 NOP 0000 NOP
0001 . 0001 . 0001 . 0001 .
0002 . 0002 . 0002 . 0002 .
0003 . 0003 . 0003 . 0003 .
0004 JUMP JOB: XY 0004 . 0004 CALL JOB: XY 0004 .
0005 . 0005 . 0005 . 0005 .
0006 . 0006 . 0006 . 0006 .
0007 . 0007 . 0007 . 0007 .
0008 . 0008 . 0008 . 0008 .
0009 . 0009 . 0009 . 0009 .
0010 END 0010 END 0010 END 0010 END

If JUMP or CALL instructions are linked to conditions (IF) , the jump is only executed if the condition is
met. If this is not the case, the instruction is ignored and the job executed further.

JOB: AB JOB: XY JOB: AB JOB: XY

0000 NOP 0000 NOP 0000 NOP 0000 NOP
0001 . 0001 . 0001 . 0001 .
0002 . 0002 . 0002 . 0002 .
0003 . 0003 . 0003 . 0003 .
0004 JUMP JOB: XY IF IN #(17) ON 0004 . 0004 CALL JOB: XY IF IN #(17) ON 0004 .
0005 . 0005 . 0005 . 0005 .
0006 . 0006 . 0006 . 0006 .
0007 . 0007 . 0007 . 0007 .
0008 . 0008 . 0008 . 0008 .
0009 . 0009 . 0009 . 0009 .
0010 END 0010 END 0010 END 0010 END

6.2.1 Instructions of the control instructions

JUMP PWAIT FOR PRINT CWAIT

CALL TSYNC IFTHEN CLS ADVINIT
TIMER ACKUEVNT ELSEIF MSG ADVSTOP
INFORM CONTR. LABEL  SWITCH ELSE DIALOG SETUALM
LIST COMMENT CASE NOP INPUT
RET DEFAULT PAUSE EI
PSTART WHILE ABORT DI

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24 E180000005GB03
6.3 Other use if JUMP
JUMP also makes it possible to jump to a different line in the same job.
JOB: AB
0000 NOP
0001 JUMP END IF IN#(20) ON
0002 START
0003 .
0004 .
0005 .
0006 .
0007 .
0008 JUMP START IF B000<=3
0009 END
0010 END

6.4 Particular feature with CALL

Maximum number of CALL

Maximum 12 x CALL behind stacked

JOB:MAIN
0000 NOP JOB: 1
0001 . JOB: 2
CALL each other, what is the amount of memory

0000 NOP
0002 CALL JOB: 1 0001 .
JOB: 3
0003 . 0002 CALL JOB: 20000 NOP
0001 .
00002 NOP JOB: A
0003 .
0004 . 0004 . 0002 CALL JOB:
0005 . 0005 END 0003 . 0001 . JOB: A
0004 . 0002 CALL JOB: 2
0006 . 0005 END 0003 . JOB: 11
0004 .
0007 . 0005 END 0000 NOP JOB: 12
0008 . JOB: A 0001 .
00002 NOP
0002 CALL JOB:
0009 . CALL JOB: A 0000 NOP 0003 . 0001 .
0010 . 0001 . 0004 . 0002 .
0002 . 0005 END 0003 .
0011 . 0003 . 0004 .
0012 . 0004 . 0005 END
0005 END
0013 .
0014 .
0015 .
0016 .
0017 . JOB: B
0018 CALL JOB: B 0000 NOP
0019 . 0001 .
0020 . 0002 .
0003 .
0021 END 0004 .
0005 END

6.5 Return instruction RET

The RET instruction permits a defined return of a job that has been called up with
CALL.
JOB: A

JOB: 9 JOB: 10
0000 NOP 0000 NOP
0001 . 0001 .
0002 CALL JOB: 10 0002 RET IF IN#(20) ON
0003 . 0003 .
0004 . 0004 .
0005 END 0005 END

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 6.6 Exercise Job 1
Task: Pick and place a component and integrate subjobs with the CALL instruction.

JOB: MAIN

0000 NOP
0001 DOUT OT#(13) OFF Lamp in key 09 off
0002 JUMP JOB:KEHLNAHT IF IN#(13)=ON Jump into the JOB FILLET
WELD
0003 END

JOB: FILLET WELD

0000 NOP
0001 DOUT OT#(13) ON Lamp ON
0002 0001 MOVJ VJ=25 start position
0003 0002 MOVJ VJ=25 Safety position approach
0004 0003 MOVJ VJ=25 Approach to component (fillet weld1)
0005 0004 MOVL V=80 Welding line
0006 0005 MOVJ VJ=25 Safety position Rotate torch
0007 0006 MOVJ VJ=25 Safety position Approach 2
0008 0007 MOVJ VJ=25 Approach to component (fillet weld2)
0009 0008 MOVL V=80 Welding line
0010 0009 MOVJ VJ=25 Safety position
0011 0010 MOVJ VJ=25 start position
0012 JUMP JOB:MAIN Jump into the JOB Main
0013 END

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6.7 Exercise Job 2
Task: Link the second JOB CIRCULAR WELD with the JOB MAIN.

JOB: MAIN

0000 NOP
0001 DOUT OT#(13) OFF
0002 DOUT OT#(14) OFF
0003 JUMP JOB:KEHLNAHT IF IN#(13)=ON
0004 JUMP JOB:KREISNAHT IF IN#(14)=ON
0005 END

JOB: FILLET WELD JOB: CIRCULAR WELD

0000 NOP 0000 NOP

0001 DOUT OT#(13) ON 0001 DOUT OT#(14) ON
0002 0001 MOVJ VJ=25 0002 0001 MOVJ VJ=25
0003 0002 MOVJ VJ=25 0003 0002 MOVJ VJ=25
0004 0003 MOVJ VJ=25 0004 0003 MOVJ VJ=25
0005 0004 MOVL V=80 0005 0004 MOVC V=120
0006 0005 MOVJ VJ=25 0006 0005 MOVC V=120
0007 0006 MOVJ VJ=25 0007 0006 MOVC V=120
0008 0007 MOVJ VJ=25 0008 0007 MOVC V=120
0009 0008 MOVL V=80 0009 0008 MOVJ VJ=25
0010 0009 MOVJ VJ=25 0010 0009 MOVJ VJ=25
0011 0010 MOVJ VJ=25 0011 JUMP JOB:MAIN
0012 JUMP JOB:MAIN 0012 END
0013 END

6.8 Exercise Job 2A

Task: Execute the training job 2 by using the CALL instruction for the call instead of
JUMP.

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28 E180000005GB03
7 Variable

Variables are placeholders. They serve to save and remember nu-

merical values, positions or characters. They are used and pro-
grammed wherever no constant states and values are used.

7.1 Variable types

7.1.1 The counter variables

Counter variables are used to save numerical values.

Variable type Range of values Address area

0 to 255 B000 to B099

-32768 to 32767 I000 to I099

-2147483648 to 2147483647 D000 to D099

-3.4 * 1038 to 3.4 * 1038 R000 to R099

7.1.2 The position variables

Position variables are used to save and edit spatial positions.

Variable type Reference axis groups Address area

Robot axis group P000 to P127

External axis group EX000 to EX127

Basis axis group BP000 to BP127

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 7.1.3 The string variables
String variables are used to save characters.

Variable type Size Address area

16 characters (e.g. ABC123) S000 to S099

7.2 Global and local variable

Local and global variables are available. Global variables are always available. Local
variables must be registered and created before in the job title.

7.2.1 Global variable

Global variables only exist one and apply equally to every job.

B001

Job 1 Job 2 Job 3

Bild 2: Global variable

7.2.2 Local variable

Local variables may exist multiple times and only apply in the job at hand.

Job 1 Job 2 Job 3

LB001 LB001 LB001

Bild 3: Local variable

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E180000005GB03 31
 Contents of local variables can be found under .

Changing between variable types Show task contents

GO BACK

PAGE

GO BACK

PAGE

GO BACK

PAGE

GO BACK

PAGE

GO BACK

PAGE

GO BACK

PAGE

GO BACK

PAGE

GO BACK

PAGE

32 E180000005GB03
7.3 Instructions for variable
CLEAR CNVRT GETS VAL SETTOOL
INC AND SQRT VAL2STR GETTOOL
SET OR SIN ASC PMT

INFORM ARITH
DEC
ADD
NOT
XOR
COS
ATAN
CHR$
MID$
SETFILE
GETFILE
LIST SUB MFRAME MULMAT LEN SETREG

MUL SETE INVMAT CATS$ GETREG

DIV GETE GETPOS STRSTR GETARG

Examples for the most common instructions

Desti
Comm Valu
natio B000 B001 B002
and e
n

SET B000 17 → 17 0 0
Set content to 17

INC B001 → 1
Add one to content (+1)

DEC B000 → 16
Subtract one from content (-1)

ADD B002 57 → 57
Add 57 to content

ADD B001 B002 → 58

Add the content of B002 to content

SUB B001 5 → 53
Subtract 5 from content

SUB B002 B002 → 0

Subtract the content from itself

SET B001 0 → 0
Set content to zero

CLEAR B000 ALL → 0 0 0

Set all from B000 to B099 to ground
→
→
→
→
→
→
→

E180000005GB03 33
 7.4 Exercise Job 3
Task: Integrate automatic cleaning of the torch in the JOB MAIN by means of variable
query.
JOB: MAIN

0000 NOP
0001 DOUT OT#(13) OFF
0002 DOUT OT#(14) OFF
0003 JUMP JOB:KEHLNAHT IF IN#(13)=ON
0004 JUMP JOB:KREISNAHT IF IN#(14)=ON
0005 CALL JOB:REINIGEN IF B025>=2
0006 END

JOB: CIRCULAR WELD

0000 NOP
0001 DOUT OT#(14) ON
0002 0001 MOVJ VJ=25
0003 0002 MOVJ VJ=25
0004 0003 MOVJ VJ=25
0005 0004 MOVC V=120
0006 0005 MOVC V=120
0007 0006 MOVC V=120
0008 0007 MOVC V=120 JOB: CLEANING
0009 0008 MOVJ VJ=25
0010 0009 MOVJ VJ=25 0000 NOP
0011 INC B025 0001 DOUT OT#(15) ON
0012 JUMP JOB:MAIN 0002 0001 MOVJ VJ=25
0013 END 0003 0002 MOVJ VJ=25
0004 0003 MOVL V=500
JOB: FILLET WELD 0005 0004 MOVL V=100 PL=0
0006 DOUT OT#(16) ON
0000 NOP 0007 TIMER T=2,5
0001 DOUT OT#(13) ON 0008 DOUT OT#(16) OFF
0002 0001 MOVJ VJ=25 0009 WAIT IN#(16) ON
0003 0002 MOVJ VJ=25 0010 TIMER T=0,1
0004 0003 MOVJ VJ=25 0011 0005 MOVL V=100
0005 0004 MOVL V=80 0012 0006 MOVL V=500
0006 0005 MOVJ VJ=25 0013 0007 MOVJ VJ=25
0007 0006 MOVJ VJ=25 0014 0008 MOVJ VJ=25
0008 0007 MOVJ VJ=25 0015 SET B025 0
0009 0008 MOVL V=80 0016 DOUT OT#(15) OFF
0010 0009 MOVL VJ=25 0017 END
0011 0010 MOVL VJ=25
0012 INC B025
0013 JUMP JOB:MAIN
0014 END

34 E180000005GB03
8 Inform list

DOUT AOUT
INFORM IN / OUT DIN ARATION
LIST WAIT ARATIOF
PULSE

JUMP PWAIT FOR PRINT CWAIT

CONTR. CALL TSYNC IFTHEN CLS ADVINIT
TIMER ACKUEVNT ELSEIF MSG ADVSTOP

LABEL  SWITCH ELSE DIALOG SETUALM

COMMENT CASE NOP INPUT
RET DEFAULT PAUSE EI
PSTART WHILE ABORT DI

WVON
WORK WVOF
TOOLON
TOOLOF

MOVJ IMOV TCPOF

MOV MOVL SPEED
MOVC REFP
MOVS TCPON

CLEAR CNVRT GETS VAL SETTOOL

ARITH INC AND SQRT VAL2STR GETTOOL
SET OR SIN ASC PMT
DEC NOT COS CHR$ SETFILE
ADD XOR ATAN MID$ GETFILE
SUB MFRAME MULMAT LEN SETREG

MUL SETE INVMAT CATS$ GETREG

DIV GETE GETPOS STRSTR GETARG

SFTON MSHIFT
SHIFT SFTOF

OPEN SAVEJ SHCKSET

OTHER CLOSE LOADV SHCKRST
INPUTB$ SAVEV NSRCHON
OUTPUTB$ DELETJ NSRCHOF
LOADJ SWAIT

DEPENDING ON THE MACRO

MACRO

EQUAL SAME INCTRUCTION PROGRAM IN OTHER LINE

USE THE SAME INSTRUCTION AS BEFORE

PREV.

Programming Language Base Standard Advanced

E180000005GB03 35
9 CUBE Space Overlap

Overlapping spaces are used to monitor certain workspaces within the working range
of the robot.
Up to 64 overlapping spaces can be defined in files. They can be created in the basis,
robot or user coordinate system.

Detection range robot

coordinates

Detection range
basis coordinates

Detection range
user coordinates

One of two different methods can be chosen to define the overlapping space:

Teaching of the space diagonal Teaching of the centre of the space

max value

TCP
min
value

36 E180000005GB03
E180000005GB03 37
 9.1 Calling up the file for overlapping spaces
This requires the EXTENDED mode
Calling up the overlapping space file.

An empty overlapping space file.

First selection between axis or cube overlap.

Entering key information.

38 E180000005GB03
9.2 Meaning of the data fields in the overlapping space

A selection is possible between a three-dimensional space overlap

(XYZ of a cube, dimensions in mm) and an axis overlap (positive and negative pulse
data of an axis).

Overlapping areas can be defined for all existing axis groups (e.g. R1; R2; B1; S1; S2
etc. )

One of the following checking methods can be selected:

a)FEEDBACK POSITION: the current position of the TCP
b)COMMAND POSITION: the current position of the TCP

This selects the orientation of the spatial axes of the overlapping area. A selection can
be made between the basis, robot or user coordinate system.

This selects whether the overlapping area is defined according to the MIN/MAX of
space coordinates or the CENTRE POSITION of the teach point.

If MIN/MAX is selected, the cursor is set to <MIN> or <MAX> and the position is set by
teaching.
If CENTRE POSITION is selected, the dimension in XYZ is entered at <LENGTH>.
The space is then set by teaching the centre point in space.

Description of the cube, e.g. cube for the start position.

E180000005GB03 39
 9.3 Special signals for the overlapping spaces
Output signals are switched when the TCP is in the overlapping area.

From SOUT#0057 to SOUT#0120 = 64 overlapping spaces.

40 E180000005GB03
9.4 Exercise Job 8
Task: Request the start position via a
virtual space (CUBE) in conjunction
with a special output (SOUT).

JOB: MAIN

0000 NOP
0001 DIN B099 SOUT#(57)
0002 JUMP JOB ERROR-CUBE IF B099<>1
0003 DOUT OT#(13) OFF
0004 JUMP JOB:KEHLNAHT IF IN#(13)=ON
0005 END

JOB: ERROR-CUBE

0000 NOP
0001 SETUALM 8000 "Robot is not in home position" 0
0002 END

Robot is not in HOME POSITION

NOTE! In order to use the instruction SETUALM, the parameter S2C400 must be set
to 1.

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10 Synchronous Programming (SMOV)

Preparatory basis for the synchronous robot movement with reference to an external
axis is the relative measurement of both axis groups e.g. R1 and S1. The calibration
defines the position of the external axis to the robot in space. However, it is first re-
quired to measure the TCP and set up the axis groups.

10.1 Checking the calibration

The check is either made directly from the robot calibration file or from a JOB with the
respective axis groups. (e.g. R1+S1:S1).
7
The synchronous movement is activated by pressing the key .
This is indicated by the following symbol in the status area.
If the external axis is moved, the robot must follow accurately.
The largest error would be visible at 180°. Subsequently switch off the synchronous
function again with the key 7.

10.2 Synchronous job

When a JOB is created, the axis group e.g. R1+S1:S1 would now be selected during
axis group selection.

Synchronous movements can only be executed with a syn-

chronous axis group.
In this example, the combinations R1+S1:S1, R2+S1:S1,
R1+R2:R1 and R1+R2:R2 can be used for this task.
After JOB has been created, the difference to a "normal"
job with R1 becomes visible: Two MOV instructions per set
are always indicated in the input buffer line. The first is for
the robot and the second line that is indicated with "+" is
for the external axis.

42 E180000005GB03
 When the points are saved, the external axis is positioned first, and the robot will fol-
low to this position. If a synchronous movement is designed, the MOV instruction will
become a SMOV instruction before the position is saved.
This is done with the key 4 .

10.3 Exercise Job 5

Task: Move around the tube at the root synchronously with the rotation of the table.

JOB: SYNCHRO-JOB

0000 NOP
0001 0001 MOVJ VJ=25 +MOVJ VJ=100
0002 0002 MOVJ VJ=25 +MOVJ VJ=100
0003 0003 MOVJ VJ=25 +MOVJ VJ=100
0004 0004 SMOVC V=100 +MOVJ
0005 0005 SMOVC V=100 +MOVJ
0006 0006 SMOVC V=100 +MOVJ
0007 0007 SMOVC V=100 +MOVJ
0008 0008 MOVJ VJ=25 +MOVJ VJ=100
0009 0009 MOVJ VJ=25 +MOVJ VJ=100
0010 0010 MOVJ VJ=25 +MOVJ VJ=100
0013 END

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11 Weaving

Weaving with the robot is used to close component gaps or to create large "a" dimen-
sions. The weaving does not change the track speed and therefore not the cycle time.
The oscillating movements are saved in special weaving files.

11.1 The weaving file

1
2
3
4
5

8
9
10

Explanation of the weaving file

1 Number of the weaving file (1 to 255 possible)

2 The mode selects the type/form of the oscillating (weaving) movement.

Single Triangle L shape

44 E180000005GB03
Explanation of the weaving file

3 Smoothing changes the oscillating movement.

Smoothen on Smoothen off

4 Defines the weaving method either based on frequency (recommended) or

movement time (often used for aluminium welding)
5 The oscillating movement is formed based on frequency and amplitude.
and Amplitude: is the half swing of an oscillation [mm]
Frequency: is the number of oscillation cycles per second [Hz]
6 Amplitude and frequency are always interrelated.
Position of the pencil Oscillation curve
amplitude

(time)

1 oscillation

Other relationships of the weaving movement result from the position of the
robot with respect to the welded seam and the TCP speed with respect to
the weaving movement.

Weaving range
Oscillating amplitude in mm

Frequency in Hz

The weaving range extends from 0.1 Hz with 50 mm maximum to

5 Hz with 2.4 mm amplitude maximum.

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 Explanation of the weaving file

7 The vertical and horizontal pattern only applies to triangle and L-type con-
tour weaving.

8 The V/H angle determines the direction of weaving.

9 The travel angle of the weaving is viewed in the working direction.

10 See operating instructions YASKAWA chapter weaving.

46 E180000005GB03
11.2 Detection of wall and floor plane
Since the robot controller only knows the programmed movements (welded seams)
and not their working environment (components), the position of the wall and floor
planes is not fully guaranteed. However, this must be known to ensure the correct ap-
plication of the angles that are specified in the weaving files to the weaving weld.

11.2.1 Easy detection of the wall and floor level

If the approach point (safety point) is set by teaching at 45° to the direction of travel,
the robot control will be able to detect the planes automatically in most cases.

11.2.2 Detection by means of reference points

If an unambiguous detection of planes cannot be assured due to operational, compo-
nent- or space-related circumstances, the planes can be defined individually and un-
ambiguously by means of reference points.

E180000005GB03 47
 11.2.3 Setting reference points
A simple weld will require two reference points. The first reference point is always set
to the position of the wall plane.

In the case of circular welds, it may be necessary to set three reference points.

The points are called up with the 0

REFP
key.
REFP1 = Wall plane
REFP2 = Floor plane
REFP3 = Direction of travel (weaving)

48 E180000005GB03
 11.3 Exercise Job 6
Task: Move fillet weld with weaving without table movement.

JOB: WEAVING-JOB

0000 NOP
0001 0001 MOVJ VJ=25
0002 0002 MOVJ VJ=25
0003 0003 MOVJ VJ=25
0004 WVON WEV#(1) weaving file 1 ON
0005 0004 MOVL V=40
0006 WVOF weaving OFF
0007 0005 MOVJ VJ=25
0008 0006 MOVJ VJ=25
0009 0007 MOVJ VJ=25
0010 END

Attention: Set reference points 1 and 2 if re-

quired

11.4 Synchronous weaving

In the case of programmed synchronous welds (SMOV), it is necessary to use syn-
chronous reference points (SREFP) and synchronous weaving instructions (SWVON /
SWVOF). If "normal" (WVON) weaving instructions are used, these will be ignored by
the controller.

E180000005GB03 49
 11.5 Exercise Job 7
Task: Expand training job 5 with weaving function and 2 reference points.
During this task, care should be taken to use synchronous instructions.

JOB: SYNCHRO-JOB

0000 NOP
0001 0001 MOVJ VJ=25 +MOVJ VJ=100
0002 0002 MOVJ VJ=25 +MOVJ VJ=100
0003 0003 MOVJ VJ=25 +MOVJ VJ=100
0004 SREFP 1 Synchronous reference point
1
0005 SREFP 2 Synchronous reference point
2
0006 SWVON WEV#(1) Synchronous weaving file 1
ON
0007 0004 SMOVC V=100 +MOVJ
0008 0005 SMOVC V=100 +MOVJ
0009 0006 SMOVC V=100 +MOVJ
0010 0007 SMOVC V=100 +MOVJ
0011 SWVOF Synchronous weaving OFF
0012 0008 MOVJ VJ=25 +MOVJ VJ=100
0013 0009 MOVJ VJ=25 +MOVJ VJ=100

50 E180000005GB03
E180000005GB03 51
YASKAWA Contacts

YASKAWA YASKAWA Europe GmbH YASKAWA YASKAWA Europe GmbH

Headquarters Robotics Division academy and Robotics Division
Yaskawastraße 1 sales office Hauptstraße 185
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Tel. +49 (0) 81 66/90-0 Tel. +49 (0) 61 96 / 777 25 - 0
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T: +43 (0)5 7000-77
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YASKAWA YASKAWA Europe GmbH YASKAWA YASKAWA Europe GmbH

academy Robotics Division academy Robotics Division
Allershausen Yaskawastraße 1 Eschborn Hauptstraße 185
D-85391 Allershausen D-65760 Eschborn
Tel. +49 (0) 6196 777 25-70 Tel. +49 (0) 6196 777 25-70
+49 (0) 6196 777 25-80 +49 (0) 6196 777 25-80
Fax +49 (0) 6196 777 25-79 Fax +49 (0) 6196 777 25-79

www.yaskawa.eu.com
[email protected]

Subject to technical changes and errors excepted.

E180000005GB03