Jaguar Land Rover

PAN Projects
Spot Welding Standard
for
FANUC’s R30iB Controller
 Robot To Spot Welding
Programming

Issue No. Details of the Update Author

1.0 Initial Release JP
2.0 Updated 5.12

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 Robot To Spot Welding
Programming

Contents
1. Introduction ....................................................................................................................... 4
2. Safety................................................................................................................................ 4
3. Robot Configuration .......................................................................................................... 5
4. IO Interface ....................................................................................................................... 6
5. SpotTool Instructions ........................................................................................................ 8
5.1 SPOT Instruction ......................................................................................................... 8
5.11Start Distance (SD) & End Distance (ED)................................................................ 8
5.12 Pressure Schedule (P) ........................................................................................... 9
5.13 SPOT ID (S)........................................................................................................... 9
5.14 Example SPOT Command ..................................................................................... 9
5.2 SET_WELD_DATA...................................................................................................... 9
5.3 Pressure Motion Command ....................................................................................... 10
5.4 Thickness Check ....................................................................................................... 10
5.5 Errors and Fault Recovery......................................................................................... 11
5.51 Thickness Check Error ......................................................................................... 11
5.52 General Weld Fault .............................................................................................. 11
5.53 Auto Error Recovery............................................................................................. 12
6. Tip Dressing.................................................................................................................... 13
6.1 TIPDRESS_CONTROL ............................................................................................. 13
6.2 TOOL(No.)_TIP_DRESS ........................................................................................... 14
7.Tip Wear Compensation .................................................................................................. 15
8. Gun Resistance Calibration............................................................................................. 16
9. Manual Pressure Check.................................................................................................. 19
9.Programming ................................................................................................................... 21
Appendix 1 – Example Spot Program ................................................................................. 22

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1. Introduction
This document only specifies the “Robot Spot Welding Programming Standard” within
FANUC’s R30iB Controller with “EtherNetIP” bus communication.

It is only relevant for JLR PAN Project installations and should be used in conjunction with
“JLR PAN Robot to PLC Standard” documentation.

The document should be read and fully understood by the end user before any
commissioning and or programming is started.

IF IN DOUBT ASK

2. Safety
The safety of people is always of primary importance in any situation. When applying safety
measures to your robotic system, consider the following:

• External devices
• Robot(s)
• Tooling
• Workpiece

Only trained personnel should operate a Robot

For more information refer to the Safety section in the:-

• FANUC Corporation SYSTEM R-30iB and R-30iB Mate HandlingTool and LR

HandlingTool Setup and Operations Manual MAROBHT8203131E REV C

The Robot E-Stop out is wired into some Allen Bradley Safe Point I/O which is then
monitored by the Line PLC. The safety of the robot is all run over Ethernet I/P safe and
utilises the Robots Safe I/O connect feature. This can make logical decision’s on Safe Inputs
on whether to issue a robot E-Stop or fence output.

Correct PPE must be worn when running the welding software in manual mode (whilst inside
the guard line), due to possible sparks or flash off caused by the weld process.

All tip dressing operations must be done from outside the guard line (safety gates must be
closed).

All safety systems must be fully functional without any manual overrides to ensure
the end user is fully protected from all hazards.

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3. Robot Configuration
Along with the standard package loaded into every JLR robot, as discussed in the ‘Robot to
PLC Standard Programming’ manual, every Spot Welding Robot will have another package
loaded into it. This will contain the following:

 Spot Welding Teach Pendant (TP) Programs:- These are stored in the TPP memory
allocation on the SRAM (non-volatile) memory of the Robot. TP programs are the
routines the Robot runs when in automatic to complete a task. All the Spot Welding
TP programs will have SPOT selected as their Application Process within the
‘Detail’ of the program (Program Detail explained later in the manual).
 Karel Programs are loaded in to the Robot to conduct certain tasks that are unable
to be done in TP language. The code for these programs isn’t visible and the
Integrator/End User are unable to edit these without the source code. Karel
programs can be called to run from TP programs just in the same way as any other
programs. For Spot Welding all the ‘DEBUG_TEXT’ and ‘DCP_FAULTS’ are dealt
with within Karel Programs.
 PMC (Programmable Machine Controller) is ladder logic that runs in the
background of the robot and is used to the communicate with the PLC, TP
Programs and third party equipment around the cell. Fundamentally PMC is a PLC
built into the robot controller as standard. This has been written and proven by
FANUC UK Ltd and MUST not be changed by the Integrator/End User.

As all the robots are configured with FANUC’s standard software package “SpotTool+” they
are able to be configured to do:-

 Spot Welding
 Dispensing
 Handling

Any robot that is going to be used as a Spot Welding Robot has already been configured in a
Controlled Start as a SPOT robot. If the robot has been configured to be a SPOT Robot and
a Handling Robot you can Toggle between the 2 Application Tools by:-

FCTN (Key) 0(Next)5(Change Appl-Tool)

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4. IO Interface
The fieldbus communication is EthernetIP and the robot acts as the master for the Bosch
Weld Timer and Controller.

The integrator/end user must set the IP address of the Bosch Controller and weld timer with
the EtherNetIP settings within the robot. This should be done in accordance with the JLR
Standard and Controls Department allocation Sheet. Follow the procedure below to set the
IP address for the Controller/Timer unit within Fanuc’s EtherNetIP settings:-

1. Press the Menu Key

2. Cursor down to I/O (5) and Press Enter
3. Press F1 (Type) and Select EtherNetIP
4. Cursor Down to the Bosch Weld Controller or Timer you want to setup, it will be
commented up as Bosch CT or Bosch WT, then cursor across to the Enable Column
Press F5(False)
5. Cursor back onto the Description Column and Press F4(Config)
6. Press Enter on the IP Address and enter in the correct IP address using the Key pad
on the Teach Pendant followed by enter,
7. Press the previous key on the Teach Pendant, cursor back to the enable column of
the Bosch WT or Bosch CT and press F4(True)

The interface for the Weld Controller is made up of 18 Bytes of Input Data and 4 Bytes of
Output Data, all these signals are pre-defined and should not be altered by the
integrator/End User. The interface for the Weld Timer is made up of 8 Bytes of Input Data
and 8 Bytes of Output Data, all these signals are pre-defined and should not be altered by
the integrator/End User.

Within the SpotTool+ software there are also some pre-defined digital IO groupings:-

 Cell Interface
 Weld Interface
 Spot Config
 Dispense

Cell interface is used as the generic signals with the cell that aren’t specific to one particular
process. These will be setup by FANUC UK and will not need modifying by the
integrator/end user.

Weld Interface is used for Spot Welding robots, digital IO signals can be entered here and
then the SPOT commands with the TP programs will have control over the IO.

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The interface also interacts with the PLC via the Robots PMC so that the process is
monitored and decisions can be made as and when necessary.

PLC Inputs
DI[97: Weld ON]
DI[98: Tip Dress In Cycle Ped 1]
DI[99: Tip Dress In Cycle Ped 2]
DI[100: Mid Cyl Tip Cmb]
DI[103: First Dress]
DI[104: Reset Tip Dress Cntrs]
DI[105: Rst Weld Tmr Tip Counts]
DI[109: Water Off 1]
DI[110: Run Mill Motor 1]
DI[112: Tip Dress 1 Swing Arm Bck]
DI[113: Tip Dress 1 Swing Arm Fwd]
DI[114: Tip Dress 1 Swing Arm Intd]
DI[118: Water Off 2]
DI[119: Run Mill Motor 2]
DI[121:Tip Dress 2 Swing Arm Bck]
DI[122:Tip Dress 2 Swing Arm Fwd]
DI[123:Tip Dress 2 Swing Arm Intd]
DI[124:First Dress]

PLC Outputs DO[97:Timer Ready]

DO[98:Weld Fault]
DO[99:Manual Weld Selected]
DO[100:Weld Contactor Fdback]
DO[101:Tip Dress Required]
DO[102:Tip Dress Pre-Warning]
DO[103:Tip Change Required]
DO[105:Tip Dress Supply CB Ok]
DO[106:Shunt Trip Operated]
DO[107:Servo Gun 1 Open]
DO[108:Do Not Mon Water Flow 1]
DO[109:Water Flow 1 Ok]
DO[110:Tip Dress 1 Contr Ok]
DO[111:Weld Transformer 1 Temp]
DO[112:Tip Dress 1 Swing Bck]
DO[113:Tip Dress 1 Swing Fwd]
DO[114:Tip Dress 1 Swing Int]
DO[115:Without Weld Monitoring]
DO[116:Servo Gun 2 Open]
DO[117:Do Not Mon Water 2 Flow]
DO[118:Water Flow 2 Ok]
DO[119:Tip Dress Contr ok]
DO[120:Weld Transformer 2 Temp]
DO[121:Tip Dress 2 Swing Bck]
DO[122:Tip Dress 2 Swing Fwd]
DO[123:Tip Dress 2 Swing Int]
DO[124:Weld On From Timer]
DO[125:Servo Gun 3 Open]
DO[126:Ok for Tip Change]
DO[127:At Tip Dress Position]

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5. SpotTool Instructions
The following instructions are specific to Spot Welding and will be what the integrator/end
user will be using when programming the robots. Other Programming instructions that are
standard to the FANUC controller can be found in the SpotTool+ Manual.

5.1 SPOT Instruction

Spot instructions tell the robot to spot weld. This section describes each spot welding
instruction. This instruction is entered on the enter of a Robot FINE move, therefore
becoming linked to that move and is executed once the robot has finished the move.

The robot is configured with a servo controlled spot welding gun therefore the following
instruction will be valid.

SPOT[SD=**, P=**, S=**, ED=**]

SD = Start Distance
P = Pressure Schedule
S = SPOT ID
ED = End Distance

For Start/End Distance and Pressure there are inbuilt Schedules within the robot that are
used within the SPOT Command. These can be found in the Data Menu inside the Fanuc
iPendant. The numbers that are entered into the SPOT Command will point at which
schedule needs to be used.

5.11Start Distance (SD) & End Distance (ED)

The value in the Start Distance (SD) and End Distance (ED) relate to the Distance
Schedule that is to be used on that SPOT. Distance schedules hold values in millimetres of
how far the each tip of the Gun should be away from the Part. The notation used for each tip
is GUN and Robot, where GUN is the moving tip of the Gun (How far the Gun needs to
move away from the part) and Robot is the static tip of the gun (how far the robot needs to
move away from the part). This motion is co-ordinated so the gun and robot move together
to achieved the required distances.

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5.12 Pressure Schedule (P)

The value in the Pressure Schedule (P) relates to the schedule number to be used on this
SPOT. The pressure schedules hold a pressure in Newton’s. As the Bosch is the master to
the robot and it will send out the required pressure it is not necessary to have multiple
pressure schedules for production programs as the robot will automatically write in the
pressure sent by the Bosch. This will be written into the pressure schedule define in the 2 nd
argument of SET_WELD_DATA. Therefore it is suggested that Pressure Schedule 1 is
ALWAYS used for production programs.

5.13 SPOT ID (S)

The value enter in the SPOT ID (S) is the SPOT ID within the Bosch Controller, when the
SPOT instruction is executed the SPOT ID is sent to the BOSCH Controller in a 32bit Group
ID.

5.14 Example SPOT Command

L P[1] 200mm/sec FINE SPOT[SD=1, P=1, S=12345, ED=2]

Start Distance (SD) = Distance Schedule 1 Used

Pressure (P) = Pressure Schedule 1 Used
End Distance (ED) = Distance Schedule 2 Used

5.2 SET_WELD_DATA
The SET_WELD_DATA program needs to be called before every SPOT command. This
program is used to retrieve the Thickness and Pressure expected for the following SPOT
command from the Bosch Weld Controller. It then writes the thickness and pressure into
Pressure Schedule that will be used on the following SPOT.

There are 3 Arguments that are passed into this program:-

Argument 1 = Spot ID(String)

Argument 2 = Pressure Schedule to be used on following SPOT
Argument 3 = Thickness Tolerance (mm) for this Spot (Optional)

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The third argument is optional, if a value is used in the third argument the thickness
tolerance in the thickness check is altered to this amount. If this argument isn’t
used/specified then the robot uses the global thickness tolerance that can be specified in
Register 19 (R[19:Global Thk Tol]).

Example
CALL SET_WELD_DATA(1-151234567,1,2)
L P[1] 500mm/sec FINE SPOT[SD=1, P=1,S=151234567, ED=2]

In the Example above you can see that the Pressure schedule used in the argument for
SET_WELD_DATA matches the Pressure Schedule used in the following SPOT. Also the
Spot ID matches as well. In this example the third argument has been used and set to 2, this
means that the thickness tolerance that will be used on this spot will be 2mm

5.3 Pressure Motion Command

In built into the SpotTool software is a pressure motion command, PRESS_MOTN. This
command works in a very similar way to a SPOT Command just without welding. The
command is used after a tip change to Press the new tips firmly into place before continuing
with welding.

Example
PRESS_MOTN[SD=**,P=**] (SD=Start Distance, P=Pressure)

When this command is ran the gun will close the tips together to the pressure specified in
the requested pressure schedule, using the Start Distance schedule as the position the gun
drives to before activating the pressure.

5.4 Thickness Check

As standard this feature will be turned on in all JLR Spot Welding robots with the tolerances
set at ±1mm (Register 19 as mentioned in 5.2). As explained in section 5.2 the thickness is
read from the Bosch weld timer and written into the Pressure schedule that is going to be
used on the next Spot. When the Spot command is ran the first thing the robot does it check
the feedback in the servo gun to compare the requested thickness against the actual
thickness. If these fall outside the predefined tolerances a DCP fault is displayed with the
following screen.

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The recovery for this fault and other examples can be found in section 5.5 Errors and Fault
Recovery.

5.5 Errors and Fault Recovery

During the cycle of the Robot there are going to be instances where we get faults during
Spot Welding, whether these be Thickness Errors (Thickness detected is out of tolerance to
the supplied thickness from Bosch), Failure to read data from the Weld Timer or a General
Weld Fault. To display and recovery from these errors a mixture of the Fanuc Software Auto
Error Recovery is used alongside the JLR standard DCP faults.

5.51 Thickness Check Error

In section 5.4 a thickness check error was explained and demonstrated. There are 2
possible ways to resolve this fault, these are to Retry the Weld or Ignore.

Ignore:-
In this instance if ignore is selected the robot will initiate the weld again but it will temporally
disable the thickness checking just on this weld and then re-enable it afterwards. Therefore
with the thickness check disable the robot will try and weld as normal.

Retry:- In this instance the robot will try to weld again and re-detect the thickness, if the
thickness falls into tolerance the robot will weld otherwise the same DCP fault will be
displayed again.

5.52 General Weld Fault

A general weld fault usually occurs when the robot has tried to weld, even has managed to
weld but no weld complete is issued by the weld controller therefore the FANUC spot tool
times-out.

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Retry:-
The robot will initiate the weld again and wait for the weld complete. If it times-out again the
same screen will appear.

Ignore:-
In this instance the weld will be skipped, no attempt to weld this spot will be made.

5.53 Auto Error Recovery

Auto Error Recovery is a piece of FANUC software that has been loaded into all JLR robots.
Auto Error Recovery allows a recovery program to be activated under certain conditions
(Alarm Codes, Digital Inputs etc) and pause the main program where it is and return to it
once the Auto Error Recovery program has been executed.

For the welding it is setup to monitor for the following system alarms on the Robot:-

1. SVGN-040 Thickness out of Tolerance – Code = 30040

2. SPOT-008 Weld Complete Timeout – Code = 23008

Up to 10 Monitored alarm codes can be used and FANUC can add more in if required. This
is not to be modified by the Integrator/End User.

The Command RESUME_PROG[1]=SPOT_ERROR is used within the SET_WELD_DATA

program, this instructs the robot that from this point if any of the monitored alarm codes are
detected the SPOT_ERROR program is to be started and the current program to be paused.
As the monitored alarm codes would normally make the robot fault and stop when the
RESUME_PROG[] command has been issued these alarms will no longer make the robot
fault, only activate the SPOT_ERROR program. Once the last spot of the welding program
has been completed the integrator/end user needs to insert the command
CLEAR_RESUME_PROG. This then deactivates the error recovery program. See Appendix
1.

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6. Tip Dressing
The Tip Dressing is controlled via the Bosch Weld Controller, this keeps track of how many
welds the Gun has done since the last tip dress. The amount of welds between each tip
dress is set internally via the Bosh Software which will be the responsibility of Bosch and
JLR to setup.

Once the tip dress interval has been reach DI-[778] Tip Dress Request is turned on to the
Robot. This signal will be checked at the end of every weld program and if the signal is high
program ‘TIPDRESSS_CONTROL’ will be executed.

6.1 TIPDRESS_CONTROL
 Used to interrogate the Weld Controller to find out which gun/electrode requires a tip
dress.
 Program Name:- TIPDRESS_CONTROL
 TP usage/notation:- CALL TIPDRESS_CONTROL
 Associated I/O:- DO[779], DI[778]
 Other Programs used:- GETWELDDATA(1-1234567,1) Argument 1 = Spot
ID/.Program No. Argument 2 = Pressure schedule to be used. In this case always 1.
Argument 3 = Thickness Tolerance for this Spot

The TIPDRESS_CONTROL program is called when the Bosch Controller is issuing DI-778
(Tip Dress Request) to the robot. The program then interrogates the weld controller to
determine which gun/electrode needs to be dressed.

First the Karel Program ‘GETWELDDATA’ is used to select program 1 in the weld controller:-

GETWELDDATA(1-1,1,2) Type

Program 1 using Type 1 is actually selecting Electrode (Gun) 1 in the Bosch controller to be
queried. Then by turning DO-[779] On (Request Electrode Status) the Weld Controller will
either turn off DI-[778:Tip Dress Request] if this electrode isn’t the one requiring a tip dress
or leave it on if it does. If it is requiring a tip dress the TP Program will then call
TOOL1_TIP_DRESS. Otherwise it will do the same process but query electrode 2, electrode
3 and so on.

It will be down to the Integrator/End user to make sure that when the program has
determined what Electrode is to be dress that the right program is called, as it is possible
that Electrode 1 could be ‘Tool 2’

Example

LBL[1: Electrode 1]
DO[779: Bosch Req Elect Stat] = OFF
CALL TOOL_2_TIP_DRESS

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6.2 TOOL(No.)_TIP_DRESS
 Program Name:- TOOL(No.)_TIP_DRESS
 TP Usage/Notation:- CALL TOOL1_TIP_DRESS
 Associated I/O:- DO[127,778,781], DI[110,778,825]
 Other Programs used:- SET_WELD_DATA, GETWELDDATA, RESETSPOTMEM,
TIP_WEAR

There are tip dress programs for each Electrode/Tool that the robot uses, e.g. Dual Spot
Welding Gun. To complete a Tip Dress the robot must activate the correct program within
the Bosch Weld Controller. These programs are as follows:-

Electrode 1:
60 = Short circuit weld
61 = Tip Dress
62 = Tip Change/First dress
63 = Polish dress
64 = Fast open (only used for pneumatic guns)
65 = Resistance calibration
248 = Current check
249 = Force check
Electrode 2:
160 = Short circuit weld
161 = Tip Dress
162 = Tip Change/First dress
163 = Polish dress
164 = Fast open (only used for pneumatic guns)
165 = Resistance calibration
246 = Current check
247 = Force check
Electrode 3:
250 = Short circuit weld
251 = Tip Dress
252 = Tip Change/First dress
253 = Polish dress
254 = Fast open (only used for pneumatic guns)
255 = Resistance calibration
244 = Current check
245 = Force check

For a standard Tip Dress that will be executed within these programs
(TOOL(No.)_TIP_DRESS) the following sequence is used:-

Example Tool 1

1. Move into the Tip Dressing position

2. Turn on DO-[127: At Tip Dress Position] and Wait DI-[110: Motor Running]

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3. Call SET_WELD_DATA set Type to ‘1’, program No. to 61 (Tip Dress) and pressure
schedule to 98.
a. SET_WELD_DATA(‘1-61’,98)
i. Pressure Schedule 98 can be changed by the integrator/end user if
the Pressure for tip dressing needs to be altered.
4. A FOR LOOP is executed for a predefined number of loops (set in the Manual Fctns
Spot Setup Page) in which a PRESS_MOTN command is used to close the gun into
the tip dresser and pressurise to Pressure Schedule 98.
5. Call SET_WELD_DATA set Type to ‘1’, program No. to 63 (Polish Dress) and
pressure schedule to 96
a. SET_WELD_DATA(‘1-63’,96)
i. Pressure Schedule 96 can be changed by the integrator/end user if
the Pressure for Polish dressing needs to be altered.
6. A FOR LOOP is executed for a predefined number of loops (set in the Manual Fctns
Spot Setup Page) in which a PRESS_MOTN command is used to close the gun into
the tip dresser and pressurise to Pressure Schedule 96.
7. After the 2 dressing sequences the gun then performs a short Circuit weld
a. Using SET_WELD_DATA(‘1-60’,1) program 60 Short Circuit Weld for Tool 1
is selected within the Bosch Weld Controller.
b. Then a standard SPOT instruction is executed
i. L P[1] 500mm/sec FINE SPOT[SD= ,P= ,S= ,ED= ]
8. Finally the robot will acknowledge the completed tip dress sequence by setting the
Tool Number to the Weld Controller using:-
a. GETWELDDATA(‘1-1’,1)
b. DO-[778: Ack Tip Dress] = ON
c. WAIT DI-[778: Tip Dress Request] = OFF
d. DO-[778: Ack Tip Dress] = OFF
e. CALL RESETSPOTMEM
f. CALL TIP_WEAR
i. TIP_WEAR is the tip wear compensation program used to alter the
TCP position based on the amount of wear seen on the tips.

7.Tip Wear Compensation

Built in to the Fanuc Robot SpotTool+ are 2 methods for the robot to detect and calculate the
Tip Wear on the servo Gun. There is the 1 and 2 step method, the 2 setup method requires
a solid bit of tooling (Such as a metal plate on a post) that the robot can use to press the tips
against whereas detection the 1 step method only requires to close the tips of the servo gun.
The 2 step method allows the calculation of wear of both tips without having to use a wear
ratio and is therefore more accurate. On the JLR X260 project the standard will be the 1 step
method.

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Figure 7.1

Tip wear will be executed at the end of each welding program and after any kind of Tip
Dressing. The wear ratio can be set via the Manual Functions screen for Spot Welding Setup
(see Figure 7.1)

There has been a teach pendant program written that can be used by the integrator/end user
called ‘TIP_WEAR’. This program can be used anywhere where there is nothing between
the tips of the Servo Gun, when this program running only Motion Group 2 (Servo Gun)
moves so the Robot (Motion Group 1) isn’t required to be in a set position.

Example

CALL TIP_WEAR(1,0)
Argument 1 = Gun Number
Argument 2 = Worn Tips (0), New Tips (1)

8. Gun Resistance Calibration

 Program Name:- GUN_RES_CALIB
Gun resistance Calibration is a manual operation where the operator runs the
GUN_RES_CALIB program from the teach pendant in T1/T2. This should only be ran under
the following circumstances:-

 Electrode ARM change

 Transformer Change
 Motor Change
 Initial Setup

The purpose of the Resistance Calibration is to calibrate the Bosch Software and the gun
together. As Spot Welding relies heavily on knowing the resistance of the welding circuit as
resistance will affect the current through the material when welding.

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When the program is executed a selection list is displayed on the screen and the operator
must select which gun the resistance calibration is to be carried out on.

Once the required gun has been selected the program steps on to run the resistance check
for that gun. The following messages will be displayed to the user.

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If No is selected the robot will end and abort the program.

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9. Manual Pressure Check

 Program Name:- MAN_PRES_CHK
o MAN_PRES_GUN1
o MAN_PRES_GUN2
o MAN_PRES_GUN3

Manual Pressure Check is a Teach Pendant program that is to be ran in T1/T2 by the
operator. It is used to check the that the pressure request by the Bosch is the pressure that
is being excreted by the robot. A pressure gauge is also placed between the tips so a real
time measurement can be observed alongside the Bosch value and the robot value. The
thickness of the gauge being used needs to be entered into the weld program on the Bosch:-

Program 249 Electrode 1 Force Check

Program 247 Electrode 2 Force Check
Program 245 Electrode 3 Force Check

On Execution of this program the robot will drive to a convenient position for the operator to
place the pressure gauge between the tips for the gun before the gun closes and
pressurises. It will be down to the integrator/end user to touch-up the positions in the
program to make it suitable for each cell and each gun (Gun 1/2/3).

When the program is executed a selection list is displayed on the screen and the operator
must select which gun the pressure check is to be carried out on. This then calls the relevant
program (MAN_PRES_GUN1/2/3).

Once the selection has been made the robot will move to its Manual Pressure position and
open the gun tips. Then the operator will be given the following instructions.

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When the pressure gauge has been placed between the Tips of the servo gun and the
operator press’ OK the robot will close the gun and pressurise to the pressure that the Bosch
Weld time asked for and the following screen is displayed.

The process can be repeated if required, but once finished the

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9.Programming
All the Spot position should be programmed with the fixed tip of the servo gun touching the
panel to be welded. The inbuilt schedules for Distance (Start/End) refer to the 2 distances in
each schedule, one being Gun and the other Robot. The Gun distance is how far the
movable tip (Gun) is away from the panel and the Robot distance is how far the static tip
(Robot) is away from the panel. See Figure 7.1 which shows the position when recording or
touching up a position, then the position when the Start distances are used, then the actual
welding position and finally the end distance. All 3 of these moves happen when the SPOT
position is activated, its best to think of the SPOT position as 3 positions in 1:-

1. Robot at weld position with the two tips at a distance away from the panel as stated
in the Start Distance Schedule.
2. Robot at the taught weld position with the Gun closed and at the pressure stated in
the pressure schedule.
3. Robot at weld position with the two tips at a distance away from the panel as stated
in the End Distance Schedule.

L P[1] 500mm/sec FINE SPOT[SD=1, P=1,S=123456789, ED=2]

Figure 9.1

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC’s R30iB Controller 21
 Robot To Spot Welding
Programming

Appendix 1 – Example Spot Program

UFRAME_NUM=0 ;
UTOOL_NUM=1 ;

COL DETECT ON ;

J PR[2:P01 Pounce] 100% CNT100 ;

UFRAME_NUM=1 ;

L P[75] 2000mm/sec CNT50 ;

L P[4] 2000mm/sec CNT50 ;
L P[76] 2000mm/sec CNT50 ;
L P[5] 2000mm/sec CNT25 ;
L P[6] 2000mm/sec CNT25 ;
L P[7] 500mm/sec CNT20 ;

! swd_gx63com_3089_3xc_056 ;
CALL SET_WELD_DATA('1-3089056',1,2) ;
L P[14:3089com_3xc_056] 2000mm/sec FINE
SPOT[SD=1,P=1,S=3089056,ED=1] ;

L P[15] 2000mm/sec CNT20 ;

L P[16] 2000mm/sec CNT20 ;
L P[17] 2000mm/sec CNT20 ;
L P[18] 2000mm/sec CNT20 ;
L P[19] 2000mm/sec CNT20 ;
L P[20] 2000mm/sec CNT20 ;
L P[21] 2000mm/sec CNT50 ;
! swd_gx63com_8200_3tr_001 ;
CALL SET_WELD_DATA('1-8200001',1) ;
L P[23:8200com_3tr_001] 2000mm/sec FINE
SPOT[SD=1,P=1,S=8200001,ED=1] ;

! swd_gx63com_8204_3tr_001 ;
CALL SET_WELD_DATA('1-8204001',1) ;
L P[24:8204com_3tr_001] 500mm/sec FINE
SPOT[SD=1,P=1,S=8204001,ED=1] ;

L P[25] 2000mm/sec CNT20 ;

L P[26] 2000mm/sec CNT100 ;
J P[27] 100% CNT25 ;
J P[28] 100% FINE ;

--eg:260R06 ;
CALL COLL_ZONE_REQ(5) ;

J P[29] 100% CNT20 ;

J P[30] 100% CNT25 ;
L P[78] 2000mm/sec CNT100 ;
L P[31] 2000mm/sec CNT100 ;

! swd_gx63com_4501_3tr_009 ;
CALL SET_WELD_DATA('1-4501009',1,2) ;

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC’s R30iB Controller 22
 Robot To Spot Welding
Programming

L P[32:4501com_3tr_009] 2000mm/sec FINE

SPOT[SD=1,P=1,S=4501009,ED=1] ;

J P[8] 100% CNT50 ;

! swd_gx63com_7880_2tr_002 ;
CALL SET_WELD_DATA('1-7880002',1) ;
L P[33:7880com_2tr_002] 2000mm/sec FINE
SPOT[SD=1,P=1,S=7880002,ED=1] ;

L P[34] 2000mm/sec CNT100 ;

L P[35] 2000mm/sec CNT25 ;
L P[36] 2000mm/sec CNT50 ;
J P[37] 100% CNT50 ;
L P[9] 1000mm/sec FINE ;

--eg:260R06 ;
CALL COLL_ZONE_REL(5) ;

L P[38] 1000mm/sec CNT25 ;

L P[10] 2000mm/sec CNT50 ;

! swd_gx63com_3053_3tr_015 ;
CALL SET_WELD_DATA('1-3053015',1) ;

L P[39:3053com_3tr_015] 2000mm/sec FINE

SPOT[SD=1,P=1,S=3053015,ED=1] ;

L P[40] 2000mm/sec CNT100 ;

L P[41] 2000mm/sec CNT100 ;

! swd_gx63com_3089_3xc_046 ;
CALL SET_WELD_DATA('1-3089046',1,3) ;

L P[42:3089com_3xc_046] 2000mm/sec FINE

SPOT[SD=1,P=1,S=3089046,ED=1] ;

L P[43] 2000mm/sec CNT30 ;

L P[44] 2000mm/sec FINE ;

! 260R06 ;
CALL COLL_ZONE_REQ(5) ;

L P[45] 2000mm/sec CNT25 ;

! swd_gx63com_7548_3tr_007 ;
CALL SET_WELD_DATA('1-7548007',1) ;
L P[46:7548com_3tr_007] 2000mm/sec FINE
SPOT[SD=1,P=1,S=7548007,ED=1] ;

L P[47] 2000mm/sec CNT100 ;

L P[79] 2000mm/sec CNT25 ;
L P[48] 2000mm/sec CNT25 ;
J P[49] 100% FINE ;

! -260R06 ;

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC’s R30iB Controller 23
 Robot To Spot Welding
Programming

CALL COLL_ZONE_REL(5) ;

L P[50] 2000mm/sec CNT100 ;

L P[51] 2000mm/sec CNT25 ;
J P[52] 100% CNT20 ;
J P[53] 100% CNT20 ;
J P[54] 100% CNT20 ;
J P[55] 100% CNT70 ;

! swd_gx63com_4517_2xc_034 ;
CALL SET_WELD_DATA('1-4517034',1) ;
L P[56:4517com_2xc_034] 2000mm/sec FINE
SPOT[SD=1,P=1,S=4517034,ED=1] ;

L P[58] 2000mm/sec CNT70 ;

L P[59] 2000mm/sec CNT70 ;

! swd_gx63com_4517_2xc_042 ;
CALL SET_WELD_DATA('1-4517042',1) ;
L P[60:4517com_2xc_042] 2000mm/sec FINE
SPOT[SD=1,P=1,S=4517042,ED=1] ;

L P[61] 2000mm/sec CNT25 ;

L P[62] 2000mm/sec CNT25 ;
L P[63] 2000mm/sec FINE ;

! 260R03 ;
CALL COLL_ZONE_REQ(6) ;

L P[64] 2000mm/sec CNT70 ;

! swd_gx63com_4517_2xc_038 ;
CALL SET_WELD_DATA('1-4517038',1) ;
L P[65] 2000mm/sec FINE
SPOT[SD=1,P=1,S=4517038,ED=1] ;

L P[22] 2000mm/sec CNT100 ;

J P[66] 100% CNT25 ;
J P[67] 100% FINE ;

! -260R03 ;
CALL COLL_ZONE_REL(6) ;

J P[68] 100% CNT25 ;

J P[69] 100% CNT25 ;
J P[70] 100% CNT5 ;
J P[71] 100% CNT25 ;
J P[72] 100% CNT25 ;
J P[73] 100% CNT25 ;
J P[74] 100% CNT25 ;

J PR[57:Near Home] 100% FINE ;

! -260R02 ;
CALL COLL_ZONE_REL(2) ;

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC’s R30iB Controller 24