ROBOTICS

Operating manual
ArcWelding PowerPac 2
Trace back information:
Workspace Main version a296 (not checked in)
Published 2019-04-12 at 11:29:24
Skribenta version 5.3.012
 Operating manual
ArcWelding PowerPac 2
RobotStudio 6.08.01

Document ID: 3HAC071361-001-001

Revision: A

© Copyright 2019 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

© Copyright 2019 ABB. All rights reserved.

Specifications subject to change without notice.
 Table of contents

Table of contents
Overview of the manual .................................................................................................................... 7

1 Introduction and installation 9

1.1 Introduction to ArcWelding PowerPac ................................................................... 9
1.2 Installing ArcWelding PowerPac ........................................................................... 10
1.3 Accessing the user interface ............................................................................... 11
1.4 Concepts ......................................................................................................... 13

2 Arc Welding ribbon 15

3 Arc Welding browsers 17

3.1 Overview ......................................................................................................... 17
3.2 Components .................................................................................................... 18
3.3 Programming ................................................................................................... 19

4 Arc Welding Functions 21

4.1 Create Process Markups .................................................................................... 22
4.2 Properties - Process Markups .............................................................................. 26
4.3 Manage Programs ............................................................................................. 28
4.4 Adding the Process Path .................................................................................... 30
4.5 Insert Air Moves ................................................................................................ 35
4.6 Move To .......................................................................................................... 38
4.7 Properties - Instruction ....................................................................................... 39
4.8 Properties - Target ............................................................................................ 41
4.9 Sync and Play .................................................................................................. 42
4.10 Manage Templates ............................................................................................ 43

5 Searching with SmarTac 47

5.1 Overview ......................................................................................................... 47
5.2 Importing search templates ................................................................................. 48
5.3 Create Search instruction ................................................................................... 50
5.4 Tool properties ................................................................................................. 52
5.5 Workflow ......................................................................................................... 56

6 Working with Arc Welding in VR 57

6.1 Overview ......................................................................................................... 57
6.2 Arc Welding VR window ..................................................................................... 58
6.3 Creating the Path in VR ...................................................................................... 67

Index 69

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 Overview of the manual

Overview of the manual

About this manual
This manual describes the key features in ArcWeliding PowerPac 2 (AWPP 2).

Usage
This reference manual contains general and specific information about the AWPP
2.0 tools and workflow.

Who should read this manual?

This manual should be used by anyone working with AWPP 2.0.

Prerequisites
The reader should have a basic knowledge of:
• RobotStudio
• RAPID
• Welding process

References

Reference Document ID
3HAC032104-001 Operating manual - RobotStudio
3HAC021272-001 Application manual - MultiMove

Revisions

Revision Description
A Released with RobotStudio 6.08
First edition

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 1 Introduction and installation
1.1 Introduction to ArcWelding PowerPac

1 Introduction and installation

1.1 Introduction to ArcWelding PowerPac

About ArcWelding PowerPac

ArcWelding PowerPac 2 brings together experience of robot and weld processes
into RobotStudio, to prepare offline programs more efficiently by utilizing the CAD
geometry as basis for all robotics programming. This method is known as
geometry-based off-line programming, it gives you unprecedented control over
the robot configurations and weld angles, resulting in more accurate weld paths.
It also extends the concept of digital robot twin by enabling the tracking the real
robot motion together with a virtual station, for improved situational awareness
and event handling, further bridging the gap between virtual and real robots.

About this chapter

This chapter will guide you through the installation process, which consists of
these steps:
• Installing ArcWelding PowerPac on page 10.
• Accessing the user interface on page 11.

Prerequisites
The following are the prerequisites for installing:
• RobotStudio installed on your computer, which fulfils the system requirements
• ArcWelding PowerPac installation package
• A license certificate
• A log on account with administrator rights on the computer

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1 Introduction and installation
1.2 Installing ArcWelding PowerPac

1.2 Installing ArcWelding PowerPac

Overview
To be able to install ArcWelding PowerPac, RobotStudio must be installed on your
computer.

Installing ArcWelding PowerPac

To install the ArcWelding PowerPac, follow these steps:
1 Browse to ArcWelding PowerPac installation package and double-click on
Setup.exe setup file.
The installation page opens.
2 Click Install ArcWelding PowerPac.
The installation starts.
3 Read the License Agreement and accept the terms.
4 Click Install.
5 When the installation is finished, complete the installation wizard by clicking
Finish.

Installing a License
Follow the procedure of installing a license as in RobotStudio.

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 1 Introduction and installation
1.3 Accessing the user interface

1.3 Accessing the user interface

Overview
Before you can start using ArcWelding PowerPac, you must load a RobotStudio
with atleast one arc-welding robot and/or the CAD model of the workpiece. The
virtual controller (VC) associated with the arc-welding robot must be loaded with
RobotWare Arc.

Loading a station
To initially open a station, follow these steps:
• On the Add-Ins tab in the ribbon, select ArcWelding from the PowerPacs
group.
• A dedicated tab for ArcWelding is added to the ribbon.
• The ArcWelding tree structure browser opens.

The user interface

The panes and windows of the user interface are described in the following figure,
which helps you to create a well-structured arc-welding program.

xx1900000812

Item Description
1. ArcWelding ribbon- Contains the general functions for arc-welding process.
tab See Arc Welding ribbon on page 15 for detailed description.
2. ArcWelding browser Organizes the components of the station and robot programs
in a tree structure.
See Arc Welding browsers on page 17 for detailed description.

Continues on next page

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1 Introduction and installation
1.3 Accessing the user interface
Continued

Item Description
3 Graphics window The graphics window is coordinated with these panes, a Paths
and Process markups are highlighted in graphic. A simulation
appearing in the graphics window is represented in the path
view by a robot cursor stepping through the path in the path
view.
This coordination is especially useful when working with
MultiMove systems.
The graphics window is an important source to input geometry
targets. By clicking on the part models in the window, you
can create or modify a target in the geometry space.
4 Tool window Enables you to create new instructions and modify existing
instructions.

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 1 Introduction and installation
1.4 Concepts

1.4 Concepts

Reference Coordinate System (RCS)

In ArcWelding PowerPac, every robtarget is associated with a local reference
coordinate system called Reference Coordinate System (RCS).
RCS is primarily used to help create and manipulate targets in RobotStudio. As
workobject/UCS, RCS can be used to set the target location and angle.
Usually a target's RCS accommodates the shape of the part geometry. For example,
for weld targets along a seam, the RCS positions are along the seam, the x axis
directions are along the path direction, and the z axis directions are along the
normal vector of the weld surface. Thus, instead of entering target values in relation
to a world coordinate or a work object, you can specify offsets and angles relative
to the RCS, which have a more direct space relationship between robot targets
and the welding seam.

en1200000334

Process Markups
Process markups are edges or joints on the CAD model which will be operated
upon by the robot.
Welders can create or assign properties to the markups, which can be used by the
programmers to set the weld speed, transport speed, process data, etc.

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 2 Arc Welding ribbon

2 Arc Welding ribbon

Overview
The Arc Welding ribbon contains all required options to create, manage and program
the markups used during arc welding.

xx1900000843

Group Button Description

Manage Process Markup To create the markups by selecting the edges.
Programs To create programs for selected markups.
Properties Properties Displays properties of the selected objects.
Verify Move To Preview the Robot motion for the selected instruc-
tions
Simulation Group Sync and Play Sync to VC and execute the movement of the
robots for the given instruction.
This option is used to sync a selected procedure
to RAPID and start the simulation on the virtual
robot controller. All related content (datatypes /
procedures) are synced automatically.
To sync and start the simulation, select a Part
Program / Path procedure and choose Sync and
play from the ribbon.
Controller Tools Motion Analyzer It track the movement of robot through online.
Freehand Freehand tools Tools in the Freehand group allows you to man-
age the movement of the robot, manage the view
of the robot system, and to select the coordinate
system.
Help About Provides the following information:
• Contents, the help file
• About ArcWelding, version information

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 3 Arc Welding browsers
3.1 Overview

3 Arc Welding browsers

3.1 Overview

Introduction
Arc Welding has two main browsers Components and Programming.
Browser Description
Components Managing Process Markups and Instruction Templates and provides to
create and manage path programs efficiently.
Programming It is used to program the markups using CAD models.

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3 Arc Welding browsers
3.2 Components

3.2 Components

Overview
In the components browser, user can select the markup and choose to view its
properties.
The components browser lists the Manage Markups and Templates in the station.
View Description
Manage Markups Markups in a workpiece organized within groups are listed in
the browser tree. User can select the markup / group to view
its properties.
Templates The process templates associated with the active Task is listed
in the browser tree with provision to create / edit the templates.

xx1900000844

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 3 Arc Welding browsers
3.3 Programming

3.3 Programming

Overview
The programming browser tree organizes path procedures in the station under
different groups and provides to change the view between Instruction and Target
modes.
Markups link the robot program with CAD model. Can be defined by customer and
passed on to programmer. Programmer uses that information to create a RAPID
program. First step to automate programming.
View Description
Part Programs Procedures that contain procedure calls to different path pro-
cedures.
Associated with workpiece / markup groups.
Path Procedures Procedures that contain process instructions.
Associated with process markups.
Services Programs Procedures related to calibration, servicing etc.
Setup Programs Procedures related to calibration, servicing etc.

xx1900000845

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 4 Arc Welding Functions

4 Arc Welding Functions

Introduction
This section describes the options within functions provided in AWPP.
• Create Process Markups on page 22
• Properties - Process Markups on page 26
• Manage Programs on page 28
• Adding the Process Path on page 30
• Insert Air Moves on page 35
• Move To on page 38
• Properties - Instruction on page 39
• Properties - Target on page 41
• Sync and Play on page 42
• Manage Templates on page 43

Continues on next page

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4 Arc Welding Functions
4.1 Create Process Markups

4.1 Create Process Markups

Overview
Using this function, you can identify (create) a process markup by selecting the
edges on the workpiece in the graphics window.
The markups are organized in the Components browser tree.
To view the window, select the Process Markup button from the ribbon, then the
tool window option is displayed.

Function

xx1800002807

Dialog Box Elements Description

Edge Count Displays the number of edges selected

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4.1 Create Process Markups
Continued

Dialog Box Elements Description

Update View Center Brings selected edge to focus automatically, to help selecting
the consecutive edge.
Name Displays the name of the Markup
Overall Edge Length Shows the total length of the selected edges.
Remove Last button Removes the last selected edge from the list.
Reverse button Reverses the sequence of the edges (changes the direction).
Existing Select Markup Select to add the new process markup under an existing markup
group
Create New Add markup under a new group.
Base Plate Search Searches for the base plate in the selected side (left-side or
right-side) with reference to the direction of the path.
Start Offset Distance from the start position of the first edge where the
markup shall start.
End Offset Distance from the End position of the Last edge where the
markup shall end.
Create button Creates the process markup and lists the same in the compon-
ents browser tree.
Clear button To clear the selected edges in the current session
Close button To close the current session

Creating the Process Markups

Use following procedure to create the process markup:
1 Click on Components tab.
2 Click on Process Markups option from the ribbon tab.
The Create Process Markup window is displayed.
3 Click on Select Edge option.
4 Select one or more edges on the workpiece of the CAD model, where the
process is to be applied. Following action are carried:
• Curves are created on the edges.
Only consecutive edges can be grouped together, which shares a
common vertex.

Note

The path is created according to the edge selection sequence.

• As edges are selected the edge parameter are listed in the window.
• The name is generated for the process markup automatically in Name
field.

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4 Arc Welding Functions
4.1 Create Process Markups
Continued

xx1800003145

5 Select the relevant mark group from the Active Markup options.
The created process markups will be listed in this groups accordingly in
component browser tree.
6 Select the relevant base plate from the Base Plate Search options.
7 If required, markup curves start and end point can be changed from Start
Offset and End Offset option.
8 Click on Create button to create the process markup.
Created markups are grouped within a workpiece and are viewed from
Components browser tree.

Note

These markups are stored as a Process Markup and is used for further
planning and path generation.

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4.1 Create Process Markups
Continued

xx1800003144

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4 Arc Welding Functions
4.2 Properties - Process Markups

4.2 Properties - Process Markups

Overview
In Component markup properties, you can view all the parameters related to the
markups created.
To view the component markup properties follow the below steps:
1 Select the Component tab in the browser window.
2 Under Process Markup, select the Process markup path.
3 Click on Properties button from the ribbon window.
The tool window option is displayed in separate window.
The properties are displayed in three tabs.
Tabs Description Figures
Workpiece Shows the markup length
tab there respective weld and
wire speeds.
These are used to com-
pute the cycle time.
Export: It exports all
markup properties to a csv
format.

xx1900000814

Parameters Used to set the welding

tab parameters for a work-
piece.

xx1900000815

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 4 Arc Welding Functions
4.2 Properties - Process Markups
Continued

Tabs Description Figures

Sequence This function is used to
estimate the approximate
cycle time by changing the
the markup sequence.
Reverse: To reverse the
markup sequence.
Change Corner: To change
the direction of each
markup, but keeping the
same sequence.
Cycle Time: Is computed
based on the markup
length, weld speed, and
transport speed defined in
workpiece and parameters
xx1900000816
tab.

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4 Arc Welding Functions
4.3 Manage Programs

4.3 Manage Programs

Overview
In the Manage programs function, you can create different types of procedures
which are organized under corresponding sections in the Programming browser
tree.
To view the window, select the Program button from the ribbon, then the tool
window option is displayed.
The following procedure types are listed
• Part - Container for path procedures calls. Associated with a Workpiece
• Process Path - Container for weld path program. Each procedure is associated
with a Markup group.
• Setup - Procedures with setup instructions
• Service - Procedures with Service/Calibration instructions
Dialog Box Ele- Description Figure
ments
Procedure Type Displays the procedure type
- Part
Workpiece Select to associate a Part Program
with a Workpiece
MarkUp Group Displays the markup group
Included Path Allows to add of path list
List

xx1800003148

Procedure Type Displays the procedure type

- ProcessPath
MarkUp Group Displays the markup group
Part program Displays the Part program

xx1900000813

Procedure name Enter the name of the procedure

Module Name Select from existing modules or
enter a new module name.

Procedure
Use the following procedure to create a process path:
1 Click on Programming browser.

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 4 Arc Welding Functions
4.3 Manage Programs
Continued

2 Click on Programs option from the ribbon tab.

The Program window is displayed.
3 Select Part from the drop down under Procedure Type option.

Note

When Part is selected the Part procedure and Path program is created.
If Path is selected only the Path program is created.

4 Select process markup group from the drop down under MarkUp Group
option.
Ensure that the Procedure type is Part.
5 Choose the workpiece to be associated with the part.
A process path is listed by default.
6 Choose the markup to be associated with the process path.
Multiple process paths can be added.
7 Click on Ok button to create the part procedure.
The newly created procedures are listed under the corresponding sections
in the Programming browser tree.

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4 Arc Welding Functions
4.4 Adding the Process Path

4.4 Adding the Process Path

Overview
Add weld instructions under Process Path for Markups. In this process, robot is
brought close to the markups and it’s reach and orientations are verified along the
markup before creating a path. This approach of robot centric programming helps
to identify and correct errors in early stages of programming.

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 4 Arc Welding Functions
4.4 Adding the Process Path
Continued

Function
The following table describes the information Create Process Path window:

xx1900000817

Dialog Box Elements Description

Show Markup Show / Hide Markups associated with the process path proced-
ure.
Base Plate Search Side Set the direction to search for the base plate for the selected
markup in graphics.

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4 Arc Welding Functions
4.4 Adding the Process Path
Continued

Dialog Box Elements Description

Select Base Plate Used to select Base plate manually.
Reverse Path Reverses the path direction indicator.
Settings Choose the Instruction template and Tool and WorkObject to
be used for the instructions that would be created.
Initial Orientation Choose the initial tool orientation on the markup. This option
is useful to quickly bring the robot to the desired position on
the markup.
Process Data XY 45,0 Tool orients at 45 deg. on the seam with reference to the base
plate.
Center of Seam Tool orients perpendicular to the seam with reference to the
base plate. Useful for V-grooves.
Orientation Adjust the tool indicator orientation with reference to the seam.
Move Robot to Curve : This option moves the robot to the selected position on the
markup curve.
Move Along Section Slider to move the robot along the markup, to verify reachability.
Select Configuration Change the robot configuration.
Reset Select markup again to restart the process.
Create Process Path Creates instructions based on the selected template.

Procedure
This function provides to create instructions for selected process markups from
graphics window. This can be accessed from the Active Process Path procedure
context menu.
Use the following procedure to create a process path:
1 Click on Programming browser.
2 Right-click on a path list under the Path procedures and select Set as active
from the context menu.
The path list gets highlighted.
3 Right-click on the highlighted path list and select Add Process Path from
the context menu.
The Process Path window is displayed and highlights all the markups in
graphics.

xx1800003141

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4.4 Adding the Process Path
Continued

4 Confirm the Tool and the Work Object from the drop-down under Settings
option in the Create Process Path tab.
5 Select the markup in graphics (selection level Curve).

Note

A tool indicator is displayed a on the curve based on the base plate

information stored with the markup. The initial tool indicator orientation is
based on the current tool attached to the robot. Hence, the robot will have
to be physically moved close to the markup curve to bring the tool to an
approximate required orientation before choosing the markup.

6 Set the Orientation.

You can modify the tool indicator orientation as required using the sliders.
7 Verify the robot Reach.
• Click on Move Robot to Curve option.
This brings the robot to the curve from current position and overlaps
it with tool indicator.

xx1800003149

Note

The tool indicator will turn red, If the robot cannot reach the curve
when clicking on Move Robot to Curve option.

• Using the slider, move the robot along the markup curve to confirm its
reach. If not reachable, the robot will not move.
8 Select the required configuration from Select Configuration option.
Displays a list of configurations and animates the motion for a selection. This
helps to verify cable twists and turns.
9 Click on Create Process Path option.

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4 Arc Welding Functions
4.4 Adding the Process Path
Continued

This adds instructions under path procedure based on the selected process
template. The instructions are organized as process sections in the
Programming browser tree.
The graphics window highlights only remaining markups for which path has
to be created.
The Reset button, clears a all the markup selection and allows to start from
beginning.

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 4 Arc Welding Functions
4.5 Insert Air Moves

4.5 Insert Air Moves

Introduction
Air instructions are added to the active path before/after the selected instruction.This
function can be accessed from the path/instructions' context menu.

Function

xx1900000819

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4 Arc Welding Functions
4.5 Insert Air Moves
Continued

Dialog Box Elements Description

Insert Before To insert air instruction before the selected instruction
Settings To define the type of air instruction. Also confirm the speed,
zone, tool and workobject.
Set Normal To Surface Set the tool normal to the surface.
Spin Towards Robot Base The tool is pointed towards the robot base.
Orient To set the orientation of the tool in the defined frame.
Selected Position Click to move the robot to the selected position.
Last segment Move robot along the last segment. Applicable if robot move to
is executed for the selected instruction.
Add Air Instruction Click to add air instruction before/after the selected instruction.
Reset To change back to the previous state.
Close To close the Add Air Move window.

Procedure
To Create air instruction, follow the below procedure
1 Click on Programming browser.
2 Right-click on a path list under the Path procedures and select Set as active
from the context menu.
The path list gets highlighted.
3 Select the Instruction from the path where the Air instruction to be add.
4 Right-click on a instruction list under the Path and select Add Air Move from
the context menu.
The Add Air Move Window displayed.
5 Set the Air Instruction as required. For information see Function on page 35.
6 Confirm the speed, zone, tool and workobject for the instruction.
7 Click on the Surface for a new position and click on Selected Position to
move the Robot to the selected position on the surface.
8 Define the reference frame and change the indicator orientation and position
in the graphical window.
9 Click Add Air Instruction to add air instruction.

To add Air instruction between two process section

1 Ensure that the path is active.
2 Select first instruction of the second process section and open Add Air Move
window.
3 Check Insert Before so that instruction is inserted before this instruction.
4 Select the first instruction of the second process section and execute Move
To.
The robot moves to the instruction and the Last segment slider in the add
air move window is enabled
5 Change the position of robot using the slider.

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4.5 Insert Air Moves
Continued

6 Change the orientation and position of the indicator in the graphical window
and move robot to the selected position or move robot by the jogging using
freehand move.
7 Select the desired configuration.
8 Click Add Air Instruction to insert a new instruction between the process
sections.
9 The air instruction is inserted as support instruction in between the process
sections.

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4 Arc Welding Functions
4.6 Move To

4.6 Move To

Introduction
This function enables user to quickly verify the robot motion along the path, to
identify reachability and configuration issues.

Procedure
To execute this function, follow the below steps:
1 Select instructions from the browser tree.
2 Invoke the Move To function from the ribbon.
The robot would execute the motion for each instruction and progress indicated
in the browser tree via an icon.

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 4 Arc Welding Functions
4.7 Properties - Instruction

4.7 Properties - Instruction

Overview
In Instruction properties, displays a tool window and moves the robot to the position,
that is, animates the instruction execution from the preceding instruction, if
available.
For a joint instruction, it displays a list of configurations and animates the motion
for a selection. This helps to verify cable twists and turns.
Use the following procedure to view the instruction properties:
1 Select the Programming tab in the browser window.
2 Select the Instruction tab.
3 Click on Properties button from the ribbon window.
The tool window option is displayed in separate window.

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4 Arc Welding Functions
4.7 Properties - Instruction
Continued

The following properties are displayed under Configuration tab:

Properties Description
Cfx Cf1 : Cf4 Axis5 Cf6 If a Joint instruction is selected, the possible configurations are
listed and allowed to modify.

xx1900000842

If a Linear instruction is selected, the reachability status is

shown.

xx1900000841

MoveTo->Joint Moves the robot step-by-step until the next joint instruction in
the path and in this process assigns the configurations for inter-
mediate linear instructions.
Joint<---> Linear Option to convert instruction from linear to joint and vice-versa.
Animation Speed Select the animation speed.

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 4 Arc Welding Functions
4.8 Properties - Target

4.8 Properties - Target

Introduction
In Target properties, you can view all the parameters related to the path created.
To view the target properties follow the below steps:
1 Select the Programming tab in the browser window.
2 Select the Target tab.
3 Click on Properties button from the ribbon window.
The tool window option is displayed in separate window.
The following properties are displayed under Offset Angles option:
Properties Description
Select Type Uses XYS or World frame
XYS - Refers to RCS frames
Selected Targets Lists the selected targets
Angles Modify orientation with reference to XYS or World frames.

Click on Apply button to apply the changes done.

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4 Arc Welding Functions
4.9 Sync and Play

4.9 Sync and Play

Introduction
For the selected process path shall be synced to RAPID with updated references
and start simulation automatically.

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 4 Arc Welding Functions
4.10 Manage Templates

4.10 Manage Templates

Overview
An process template is a collection of process parameters and instruction settings
that define the properties of a weld.
The process templates are based on several instructions. For example, the Move
template includes instructions for MoveL, MoveJ, and MoveC. These default move
instructions are always available in RobotStudio. The process templates are created
upon Activation of PowerPac, based on the available instructions in RobotStudio.
they are saved in XML format within the RobotStudio station. Each motion task
would have separate templates.

xx1900000826

xx1500002107

Note

The Arc process template is not created automatically, when Arc Instruction
template is imported after activating the PowerPac.

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4 Arc Welding Functions
4.10 Manage Templates
Continued

Process templates

WARNING

Do not manually modify or delete any process definitions in Instruction Template

Manager.
Click on Components tab and under Templates option, select the templates.
Right-click on the selected templates to access the available options. The following
figure and table provide more information about the available options.

xx1900000827

Menu Description
Edit... View and modify the properties of the selected application
template.
Create Copy Creates a copy of the selected application template.
Save As Saves the selected application template with a new name.
Delete Deletes the selected application template.

Modifying an process template

To modify an application template:
1 Right-click on the template and click Edit.
The Manage Arc Processes window is displayed.
2 Modify the template according to your requirement.
3 Click Apply button.
The changes are saved.

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4.10 Manage Templates
Continued

xx1900000828

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4 Arc Welding Functions
4.10 Manage Templates
Continued

The following table provides the description of the Manage Arc Processes window:
Section Description
Process Description You can modify the description about the template.
Instruction Type Lists the types of instructions available with for the selected
template.
• Approach
• ProcStart
• ProcVia
• ProcEnd
• Depart
For the selected instruction type , the corresponding Available
Instruction and Instruction Parameters are displayed. You can
edit the parameters from this section.
Approach/Depart Select the Add Approach/Depart check box to enable the ap-
proach/depart parameters.
Offset Values
You can edit the approach/depart parameters from this section.
Available Instructions Displays the available instructions for the selected instruction
type.
Instruction Parameters Displays the instruction parameters for the selected instruction
type.
You can edit the parameters from this section.

Note

The check box ensures the same argument value is used as

for other instruction types.

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 5 Searching with SmarTac
5.1 Overview

5 Searching with SmarTac

5.1 Overview

Search templates
A search template is a search instruction and the selected template will be used
to create a search instruction when the Create search function is executed. There
are seven predefined search templates available in ArcWelding PowerPac. All
these templates require that the controller have the SmarTac option installed.
ArcWelding PowerPac supports both the Search_1D.
Before you can start creating searches based on the imported search templates,
you must define the tool geometry. ArcWelding PowerPac needs to know the gas
cup diameter and wire stick-out when calculating torch angles based on the search
parameters.

Search_1D
Search_1D is a RAPID instruction used for tactile searching of a feature with
SmarTac. The search path is described by two required robtargets. The search
result is stored as a pose data in the required argument Result. All SmarTac board
activation and deactivation is automatically handled.
Example:
Search_1D peOffset,p1,p2,v200.tWeldGun;
When executed, the robot makes an L move to the start point p1. The SmarTac
board is activated and motion starts towards the search point, p2. The robot moves
on a linear path from p1 to p2. The robot will continue past the search point for a
total search distance described by twice the distance between start point and
search point. When contact is made with the part feature, the difference between
the contact location and p2 is later stored in peOffset. The program displacement
can be later used to shift programmed points using the RAPID instruction PDispSet.

Wire Searching vs. Gas Cup Searching

Sometimes it is necessary to search with the welding wire, rather than the gas cup.
This is possible in some systems with the necessary optional hardware installed.
The SmarTac instructions are designed to handle this. Search_1D has an optional
argument, \Wire, that will switch the signal to the wire.

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5 Searching with SmarTac
5.2 Importing search templates

5.2 Importing search templates

Overview
Importing search templates is a two-step procedure: first, motion instruction
descriptions must be imported or created, then the search templates can be
imported or created.

Import or Create Motion Instruction Descriptions

The search templates are based on one or several instructions. For example, the
instruction Search_1D is available in a controller with the option SmarTac installed.
To be able to configure a Search_1D instruction in RobotStudio, it is necessary to
tell RobotStudio how these instructions should be handled. This can be done
manually in the Instruction Template Manager in RobotStudio or by Adding the
instruction definition.

xx1900000838

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 5 Searching with SmarTac
5.2 Importing search templates
Continued

xx1900000839

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5 Searching with SmarTac
5.3 Create Search instruction

5.3 Create Search instruction

The Create Search Instruction Dialog Box

The Create Search windows form is accessible from the context menu of the
instruction.

xx1900000835

Object Description
Search Object Shows the instruction before / after which the Search instruction
would be inserted
Search Name The identifying name assigned to the search sequence
Search Template Choose between:
Gas cup search
Search_1D

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5.3 Create Search instruction
Continued

Object Description
Search Point Enables and shows the graphically selected surface, together
with the Tool indicator.
Search length The distance in millimeters between the StartPoint and the
Search Point of the search move, perpendicular to the surface.
Modify Orientation Allows to modify the tool orientation along the XYS planes.
MoveTo Brings the robot to the graphically selected position with either
the Gas-cup or Wire.
Create Instruction Creates the Search instruction at the selected position
Show Properties Form Opens the Tool Properties form.

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5 Searching with SmarTac
5.4 Tool properties

5.4 Tool properties

The Tool Properties Dialog Box

The Tool Properties dialog box is launched from the Create Search window form.
The Create Search window form is launched from the instructions context menu
of the active path procedure.

xx1900000836

Section Description
Select Tool Displays the attached tool gun.

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5.4 Tool properties
Continued

Section Description
Selected Property Displays the search type option to use for the welding.
• BottomOfGasCup: Indicates the bottom of the gas cup.
Associated with Search_1D template
• SearchHitPoint: The point on the gas cup that will hit the
searched feature when performing a GasCup search.
Associated with Gas Cup Search template
Radius Adjust the radius parameter to suit the position on the gas cup.
Z axis Adjust the position on the gas cup.
Wire Size Use to change size of the wire.

The following tool properties of the search.

These properties are set by adjusting the Radius, Z-axis position interactively on
the tool geometry

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5 Searching with SmarTac
5.4 Tool properties
Continued

Object Description
Gas cup hit pointl The point on the gas cup that will hit the searched feature when
performing a GasCup search.

en1200000300

Bottom of gas cup Indicates the bottom of the gas cup.

en1200000302

End of contact tip Indicates the end of the contact tip. This information, along with
the TCP information, is used to calculate the wire stick-out.

en1200000304

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Continued

Object Description
Wire diameter The diameter of the wire.

en1200000305

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5 Searching with SmarTac
5.5 Workflow

5.5 Workflow

Procedure
1 Ensure that the Search Templates are Instructions are available in
RobotStudio.
2 Select the instruction and choose to launch the search window form.
3 Navigate to the Tool properties window and validate the position properties
either Gas cup or Wire search type.
4 Return to the Search form.
5 Select the search template.
6 Click to select the search point on the graphics window, this shows a tool
indicator for the selected surface.
7 Adjust the tool orientation in different planes.
8 Select to Move the Robot – Note that the Robot moves to the positions with
the active Hit point, this may be either the Gas cup or the Wire.

xx1900000834

9 Iteratively adjust the Tool orientations about the selected point.

10 Select the Create instructions button and note the instruction is inserted in
the browser tree..

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 6 Working with Arc Welding in VR
6.1 Overview

6 Working with Arc Welding in VR

6.1 Overview

Introduction
Refer to RobotStudio document for more information on Virtual Reality.

Getting started
• Make sure that the complete hardware is connected and ready to use.

Note

Refer to RobotStudio document for more information on Virtual Reality.

• Make sure that the process markup is created, before you start the VR
session.

xx1900000614

Use the following procedure to setup the VR:

1 Open the RobotStudio.
2 Click on the Add In tab and select the ArcWelding2 option, to activate the
ArcWelding PowerPac 2.
3 From the ribbon tab, select the Virtual Reality option, to activate the Virtual
Reality.

Note

The graphical window is made active for VR.

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6 Working with Arc Welding in VR
6.2 Arc Welding VR window

6.2 Arc Welding VR window

Introduction
Use the mechanism to select the Process Tools window using the PAD.

xx1900000601

The following modes are displayed in the window:

Mode Description
Select Path Used to create and test the path.
Also sets the active controller, tasks, and paths.
Move To Used to move the robot along the selected instructions and to
check the reachability of robot from the previous target position.
Also, used to set the configuration.
Jog Util Used to jog the mechanism by grabbing the robot axis or re-
motely.
Add Process Used to add weld process sections to the active path procedure.
Add AirInst Used to add air instruction to the active path procedure.

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6.2 Arc Welding VR window
Continued

Select Path Mode

When the Select mode is selected, the following options are displayed:

xx1900000602

Mode Description
Controller Name Set the active controller name.
Active Task Used to set the active task.
Select Path Used to select a path from a list of path procedures. Only the
selected path is visible. The selected path is made as the active
path.
Create Path Sets the active workobject and the tool.
Used to create empty path with an ActUnit instruction.
Select Inst Used to select an instruction for the path selected. The inform-
ation for the selected instruction is displayed.
Test Path Used to verify the selected path. The selected path is the active
path.

Use the following procedure for selecting and creating a path:

• To create a new path click on the Create Path option, an empty path will be
created.

Note

The ActUnit instruction will be inserted as the first instruction, when a new
path is created.

• A path can be selected either by selecting it from the drop down or by

pressing TRIGGER button when highlighted.
• Only the selected path is visible and the selected path is made active.
• The Test Path option is used to verify the active path.

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6 Working with Arc Welding in VR
6.2 Arc Welding VR window
Continued

The information text will be shown for a few seconds in the current instruction and
active work-object, when selected with the controller. Info text can be removed or
brought up by pressing the PAD or A button (Oculus).

xx1900000612

Move To Mode
In Move To mode, you can move the robot to the selected instruction by pressing
the TRIGGER.
When the Move To mode is selected, the MoveTo Options window is displayed
with following modes.

xx1900000603

Mode Description
Show Config The robot configurations are shown. The configuration can be
modified for the MoveJ instruction. The configured pane is
shown only after the robot has reached the selected target.
Conv -> J To convert the instructions from linear to joint.
Conv -> L To convert the instructions from joint to linear.

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Continued

Mode Description
Conv -> C To convert the instructions from linear/joint to circular.

Use the following procedure to check the robot reachability from previous position
and to change configuration:
• Click on Move To mode.
The MoveTo Options window is displayed.
• Select the instruction by pressing the TRIGGER.

Note

The robot will move to the selected target position from the previous target
position.

• Click on the Show Config mode, to change the configuration of robot.

The configuration pane window is displayed.

xx1900000604

• Check the movement of the robot by selecting the configuration for the
selected instruction.
• The configuration can be modified for the selected instructions.

Note

The configuration pane is shown only after the robot has reached the
selected target.

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6.2 Arc Welding VR window
Continued

Note

Configuration pane. The most likely configuration is listed first.

Jog Utility Mode

When the Jog Util mode is selected, the Jog Options window is displayed with
following modes.

xx1900000610

Mode Description
Robot Name To select the robot mechanism.
The Robot name is displayed.
Joint Jog To move the Robot to the selected position by grabbing the
axis and moving it or by the utility.
Select Config To select the desired configuration.
Move Home The Robot moves to the home position.

Use the following procedure to jog the robot:

• The Jog Util mode is virtual tool that is used to jog a mechanism without
grabbing it. It is useful for mechanism that are hard to reach.
• Mechanism is selected with a drop down.
• The absolute position of the axes are shown in joint jog mode.

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6.2 Arc Welding VR window
Continued

• Also, for the robot configurations are shown in a list.

xx1900000611

Add Process
The Add Process mode is used to create welds.
When the Add Process mode is selected, the Selected Process window is
displayed with following modes.

xx1900000605

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Continued

Mode Description
Select Inst Used to select the instruction.
Rev Direction Select this mode to reverse the wire direction
Search Left / Search Right Select left or right side. The side defines the side of the wire to
search for the base plate.
Use Templ Used to select the process template.
Create Proc Select this mode to create the weld (process section).

In the Add Process mode you can create the process section for the selected path
procedure.
Use the following procedure for creation of the process section:
1 Select the process markup where the weld need to be created. For more
information see To select the process markup on page 64
2 Move the robot to the selected markup to create the weld. For more
information see To move the robot to selected markup on page 65
3 Click on Create Proc option, to add the welds to the selected path.

To select the process markup

Use the following procedure to select the process markup:
• Move the controller close to a wire. A coordinate system will be shown that
indicates direction of the process and the base plate (blue arrow).
• Select left or right side. The side defines the side of the wire to search for
the base plate (blue arrow). Example is a right side configuration shown in
figure.
• When a wire is selected, the direction of the wire can be modified.
• Hold the thumb on the PAD to keep the position on the wire.

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Continued

To move the robot to selected markup

Use the following procedure to move the robot to selected markup:
• Robot can be moved along the selected section by pressing the TRIGGER
button at the same time as the controller is moved along the section. The
tool orientation will be kept in relation to the wire.
• Click on Use Template and select the desired template from the drop down.
• The orientation of the tool can be modified by pressing the LEFT TRIGGER
button at the same time as the right controller angle is changed.
• A weld (process section) can be created by pressing Create Proc option.

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Continued

Add AirInst
This is used to add air instruction before or after the selected instruction.
When the Add AirInst mode is selected, the Select Move Type window is displayed
with following modes:

xx1900000606

Mode Description
Linear Move Used to create linear air move instruction.
Joint Move Used to create joint air move instruction.
Robot execution Speed To select the speed of the robot while executing air instruction.
Select Inst To select the instruction.
Snap Vertex The closest vertex will be selected.
Set Normal The tool will be normalized to the selected surface.
Auto Spin The x axis of the tool will be pointing towards the robot base.
Insert Before Used to insert the instruction before to the selected instruction.
Add AirInst To create air instruction before/after the selected instruction.

Use the following procedure to create an air instruction:

• Select the position where air instruction need to be created by pressing the
TRIGGER. Robot moves to the selected position.
• By pressing the Add AirInst button an air instruction will be added to the
selected path.

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 6 Working with Arc Welding in VR
6.3 Creating the Path in VR

6.3 Creating the Path in VR

Procedure
Use the following procedure to create the path in VR:
1 Click on Select Path mode.
Set the active task, workobject and tool.
For more information, see Select Path Mode on page 59.
2 Click on Create Path option, to create an empty path.
3 Click on Add Process mode, to add weld process.
The Selected Process window is displayed.
For more information, see Add Process on how to add the process path.
4 Click on Add AirInst mode to add the air instruction to the active path
procedure.
For more information, see Add AirInst on page 66 mode.
5 Click on Move To mode to make sure all the target are reachable by robot
from the previous position.
For more information, see Move To Mode on page 60 mode.

Note

If the targets are not reachable the robot will stop automatically.

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This page is intentionally left blank
 Index

Index R
RCS, 13
Reference Coordinate System, 13
A
ArcWelding PowerPac S
User Interface, 11 Search_1D, 47
G T
Generic Data, 13 Template
Searching Template, 47–48
I Tool Properties, 52
Instruction
Search, 50

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ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400

ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000

abb.com/robotics
3HAC071361-001-001, Rev A, en

© Copyright 2019 ABB. All rights reserved.

Specifications subject to change without notice.