BOS6000 & UIR Adaptive Weld Control

BOS6000 & UIR Adaptive Weld Control
PSI6000 Inverter
BOS6000 & UIR-Regulation
Hardware and Software
Training Package 2010
Klaus Klick
DCC/SVC15
Version 1.36.0 Aug 2010
Electric Drives and Controls 1

© All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.
We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination.
Contents Page 1
System overview Pg 7
Welding Sequence Pg 10
Hardware configuration Pg 13
Timer standard configuration Pg 15
Timer Name & I/O configuration Pg 17
Software communication Pg 22
Ethernet configuration Pg 23
BOS 6000 Software Pg 25
Programming page Pg 29
Icons Pg 30
Welding Sequence Pg 31
Programming exercise Pg 35
Copy Parameter Pg 36
Copy Programs / Timer Pg 37
Current Monitoring Pg 46
Extended Welding Sequence / Pressure Profile Pg 52
Contents Page 2
Heat Stepper Pg 53
Heat Stepper & Tip dressing Pg 55
General set-up Pg 56
Electrode set-up Pg 58
Power Unit set-up Pg 62
I/O Diagnosis Pg 63
Simulate Start Pg 66
Timer Information Pg 67
Last Weld Pg 68
Plant Layout Pg 69
Log In / Compare Pg 72
Protocols Pg 76
Overview Pg 80
Error Table Pg 81
Pre-Warning F2 Pg 83
Correction Pg 87
Contents Page 3
Force Calibration Pg 89
Current Calibration Pg 96
Set Up Heat Stepper Curves Pg 106
Set Up Tip Dresser Curves Pg 107
Backup Pg 108
Restore Pg 111
Help Page F1 Pg 116
How to extract spatter data Pg 118
Sheet thickness calculation and output Pg 125
UIR Regulation system Pg 129

UIR Installation Pg 133
UIR Operation Pg 134
General Parameter Pg 138
Program Parameter Pg 139
Monitoring Parameter Pg 143

Contents Page 4
Setting of weld parameter for UIR Pg 146

Viewing UIR-Curves Pg 152
Generating Reference Curves Pg 155
Activating UIR-Regulation Pg 163
Monitoring Parameter Pg 166
Reaction of the UIR Regulator Pg 171
Diagnosis UIR Pg 173
Reference Gun Resistance Pg 175
UIR Fault condition Pg 179

System Overview

Welding Equipment
Mains Input
Rectification Machine Interface,

I/O Bussystem
DC-Link
Pressure / Force (0 -10VDC)
Inverter
1 kHz Current-Feedback
24 VDC Supply /
Voltage-Feedback Stop Circuit
Voltage-Feedback
Current-Feedback Welding
Welding Gun
Gun
Overview PSI6000 Inverter and Transformer
Primary sensors
for KSR
Inverter output
500V 1000Hz to the
Gun
Secondary coil (KSR)
UIR Connections
Typical ouput 5-12v DC

4 – 120kA, 1000Hz
depending on
Transformer
Configuration.

Welding Sequence
F = Force [kN]
I = Current [kA]
t = time [ms]
Gun close open
Weld Current
SQZ WLD HLD

Electric Drives and Controls
Squeeze time Weld time Hold time
10
Resistance Welding Process Basics
Electrode 1
Contact-resistance Electrode-Sheet1
Sheet 1 Material-resistance 1
Contact-resistance Sheet-Sheet
Sheet 2 Material-resistance 2
Contact-resistance Electrode-Sheet2
Electrode 2
Electrode-Force F [kN]
Current I Q = R x I² x t
[kA]
Hardware Familiarisation

Bosch Rexroth Welding Control Panel Device
Familiarisation typical setup
4.) Signal lamps
5.) Main Switch
7.) 2x PST6250.333L1
8.) 2x Main Switch
9.) Fuses

Bosch Rexroth Welding Control Panel Device
Familiarisation typical setup
Roboter bus system (optical Interbus)
24VDC Supply Input
Bosch Rexroth Welding Control (timer)

Timer Standard Configuration
I/O Card slot

Adaptive control
slot
Field bus module
slot
Side View

Understanding Weld Timer Type Codes
Welding controls
PSI6300.100L1
PSI6300.333L1
PSI6300.350L1
PSI6300.773L1
PSI63C0.357L1
PSI63S1.259L1
Transformers
PSG6130
Timer Configuration PSI 6100.333L1
Interbus I/O
Serial Com
24 Volts internal /
external supply, see
next page.
Parallel I/O
External pressure
control to prop valve
Secondary current
feedback,
Transformer temp
feedback.
Output to the
transformer 17
24volts Distribution
Internal links

External Fan Operation
The fans are normally located at the rear of the panel, forcing air
to be driven across the fins of the heat sink.

Proportional Valve Control and feedback
+24volt feedback, from the prop valve, tells the welding control
that the demanded pressure has been reached, this then allows
robot control to give the command to close the gun and allow the
weld schedule to commence.
If no prop valve is used, then +24volts and 0volts must be
supplied to pin 4 & 2 !!
Transformer Feedback
Industry Standard is 150mV / kA. This

is adjusted automatically during a
calibration procedure to suit the
individual application
A normally closed contact in the

transformer, feeds back temperature
OK. If no feedback is available, then
these pins must be shorted.

Software Communication
Wiring schedule for the Serial port
Software Communication is
normally via a specific
communications card, via
Interbus / Ethernet…etc.
You can also connect directly
to individual timers via the
serial port, X1

Ethernet Communication configuration
When connecting via an Ethernet link, please ensure

you have set the I.P address correctly on the
computer, otherwise no communication will be
possible.
This indicates that your computer has detected a local
area connection.
To access the IP setting, double click the icon, with
your mouse.
If you do not have this icon present, select the

option below

Ethernet Communication Configuration
The General tab will A further Ensure that the IP address you select does not
now become visible configuration screen exactly match the IP address of the Timer, the
will appear last digit should be different
Select Properties
Select Internet Protocol (TCP/IP) then OK
Select, Use the following IP Address then OK
Setting the IP Address Enter an IP Address and subnet mask then OK

BOS6000
BOS6000 Software Familiarisation

BOS6000 Username & Password

Timer Reference
2. Add the timer name

3. Add any reference
comment
4. Select your
communication method.
V24, Ethernet….etc
5. If you are connecting
via Ethernet, then insert
the IP address here
6. Select Online or Offline
mode
7. Select protocol to
enable the UIR monitoring
8. Select the direction of
data flow, on initial
communication
1.To add a new or additional 9. When the information
timer, select the Add button has been installed, press
first, the Add/change Timer OK
box will then appear above
10. Select continue button
27
We also retain sole power of disposal, including all rights relating to copying, transmission and dissemination. to access the program
Timer Status
Monitor the Status and

Description window, if a red bar
appears and stays then there is
a problem with your
communication path, cable, or
the timer may be switched off.
Monitor the Status and Description

window, a yellow bar should
proceed a green bar.
This indicates that communication
path is operational, and the
database is being populated with
the timer information.
Please be patient, on the initial
start-up it can take several minutes
to gather all the data for the
database.
All subsequent connections will only
Electric Drives and Controls take seconds to get on-line 28
Program Page
Programming
The spot number, program
and communication status is
found at the top of program
page, as well as the drop
down menu’s
The raised tab indicates the

page that is currently being
viewed
Nearly all functions/pages

can be quickly accessed via
the “icons” that are situated
at the top of the pages.
A single click will select the

required page, and another
single click will return you to
your previous screen.

BOS6000 Icons
Error Table Plant layout

Protocols
Compare
Pre-warning Table
Parameter Overview,
for incorrect parameters
Login
Spot reference
Comments
Rights
Administration
Timer
reference
Overview
Spot reference
Table
Program Page
Correction
(Parameter data) Diagnosis
Set-up
(i/o interface)
30
Sequence
The BOS6000 software

only shows tabs, which
are available.
e.g: PSQ-Tab is
only shown, if XQR PCB
is mounted in the timer.
The BOS6000 software

only shows parameter,
which are accessible.
e.g: COOL 2 time is
only shown, if the
number of impulses is
bigger than 1.
Monitoring parameters
are only shown, if
kA-monitoring is “ON”

Program tabs
Programming
By selecting individual tabs within the

pages you can navigate around the
software at the click of a button
Dependent on the timer status, you can

see if the timer is online, or offline.
Blue is working offline
Green is working online
You can also see at a glance if the weld

has a pre-heat, a post heat, or even if
upslope or down slope.
Sequence
Programming
The sequence screen allows
the user to see the
programmed weld Program
parameters at a glance Timer
Pressure
Weld time
Squeeze Weld current Hold
For PSI6000 inverters the

times are all programmed in
milliseconds.
PST6000 timers are

programmed in cycles
1 cycle = 20ms

Sequence
To select a weld program:- to

access the required program,
simply select the program from
the up/down buttons, or type in
the actual program number. The
electrode number will update
when a program is selected.
To select a spot number:-

utilising the down arrow select
the required spot number, and
the program that is associated
with it will automatically appear
Inhibit Seq (P) (Inhibit this

program sequence)
This needs to be set to “Off”, if
not then the weld sequence will
be inhibited for this program only
Weld On/Off Int (P) Sequence:- There are 3 sequence options,

(Internal weld on/off) Single: 1 weld sequence per start signal
Repeat: 1 weld sequence repeated until the start signal is dropped
This needs to be set to “On”, if
not then the weld will be turned Seam: 1 weld permanently on till the start signal is dropped
Off for©Electric
thisDrivesprogram only
and Controls
All rights reserved by Bosch Rexroth AG, even and especially in cases of proprietary rights applications.
34
Programming exercise
 Please enter the

following Weld programs
 Step1: Prog1 – 2
 Step2: Prog3 – 5

Programming exercise Copy1
If you select one

Parameter,
2) You may copy

this parameter
Using the right
mouse button
1) You see the input range of this parameter

Programming exercise Copy2
Using the Copy feature from the main menue, you have all Options
to copy any data from the weld timers.

Sequence
Regulation:- Mix or
Standard
If Standard is selected then

weld 1 and weld 3 can only
be programmed in the same
mode as weld 2
If Mix is selected, weld 1 &

weld 3 can be programmed
in PHA (phase angle) or
KSR (constant current)
mode

Sequence
*see illustration on the next sheet
Monitoring:
Mix or Standard
Standard mode: the actual
current is determined by the
complete weld cycle including
any cool times
Mix mode: the actual current
is determined by the individual
weld times

Sequence

Sequence
PHA: Phase Angle Regulation

Programmed in scale units %,the greater the %Ht, then
the greater %age of current flowing
Phase angle, fixed value

Half-cycle of determined by program
mains voltage
31° 130 ° - Electrical degrees

0° 180 °
120 99 0 -15 - Scale units (%)

High current Programmable range Low current
Principle of Unregulated Phase angle welding

Principle of Constant current regulation

Sequence
Electrode:
0 – 31 different electrodes
can be selected, dependent
on your firmware version
Reweld:
If this function is activated
and a low weld current
occurs with the start signal
still high, the control will
automatically attempt to
reweld the program, if the
weld is low again a weld
fault is output.
Note:- if there is no current,
then a reweld will not be
activated
Sequence
Impulse:
This function indicates how
many times the weld 2, cool 2
function is repeated during one
weld sequence.
If the impulse function has a

figure greater than 1, then
the portion of the program
that is inside the green
shape is repeated however
many times is programmed

Sequence Current monitoring
Current monitoring:
When the monitoring is

activated (ON), the
reference current and all the
tolerance band parameters
become visible

Sequence
1
Repeat factor, is the number
2
of consecutive welds allowed
3
in the conditional permissible
4
tolerance band;
if this occurs, the actual
figure is displayed here
2
3

Sequence
Ref, kA is the
programmed reference
current
Act. Ref. kA is the
actual current
achieved
Average PHA is the
actual Phase angle
required to achieve the
required current

Spot table
In the spot reference table a particular spot name is linked to a program number and a
timer.
This allows selection of spots by their individual name.
Important: The Spot reference table must be transferred into the timer to get active!!
3.) 1.)
2.)
Spot table
4.)

Sequence
If this Icon is coloured, then

when pressed, the
comments sheet for the
actual spot number that is
assigned to this program will
be displayed
The number of comment

fields can be altered in the
Config tool

Extended Sequence
from this page the pressure

profile function can be activated.
When the profile is activated the

force can be programmed to a
specific value at any time during
the weld sequence.
The force can be altered up to 10
times during the weld process

Heat Stepper
Heat increase %
in the lifetime of
electrode caps
Heat stepper:-
activation on/off
Warn Wear:-
Wear factor:- Number of welds
individual welds can be before the end
given a greater or of the max-life,
lesser “weighting”, that pre-warning
Max Wear:-
dependent on the becomes active
actual wear to the tips The number of welds over which the (50)
heat is stepped (incremented)
Wear/comp:- The
number ofElectric
welds taken
Drives and Controls 53
to complete
© All one cycleby Bosch Rexroth AG, even and especially in cases of proprietary rights applications.
rights reserved
Heat Stepper
Heat increase
% between tip
dresses
Max Wear:-
The number of welds over which the
heat is stepped (incremented)

Heat Stepper and tip dressing
Please note:-
The Max life is
calculated by the
multiplying
(Max Wear x tip dress Tip Dress Steps:-
steps) + Max Wear The number of dress
steps (10)
i.e. (500 x 10) + 500 =
5500 welds
Dress-Request:- The
number of welds before
the max wear that the tip
Heat increase dress request output is
% between tip activated
dresses
Max Wear:-
Dress new Electrode:- The number of welds over which the i.e. 5450 welds
The weld is heat is stepped (incremented) (500)
inhibited, until the gun
is dressed,
immediately after the
electrode
We also retain sole power of disposal, has
including all rightsbeen
relating to copying, transmission and dissemination.
General set-up
If activated the weld will be

inhibited when max life is
reached
The (S) indicates that the
function will be activated for
ALL programs Mode Pressure Output:
Max Weld Time, this is the There are several
control of the max weld options for pressure
time, for all programs output, 4-20mA, 0-
20mA, 0-10V output to
the prop valve
This parameter Inhibits the
current Monitoring on All
programs
Current measurement
selects the type of
Max Rewelds:- this the
monitoring, either
number of consecutive
secondary or primary
rewelds at one position
A measuring loop check is a verification of the current sensor in the secondary circuit.
On : Measuring loop test active, sensor faults are detected. .
Electric Off : Measuring
Drives and Controls loop test not active, sensor faults are not detected. 56
General set-up
The Fade out time parameter is used to suppress the natural
current rise at the beginning of the weld time for current
measurement
The Trail current parameter is used to activate or deactivate

measurement of the trail current after the last weld time.
On : The trail current is included in the measured result.
Off : The trail current is not included in the measured result.
Both settings in BOS6000 must match the settings of the
external current meter for comparative measurements.

Electrode Set-Up
The %I Prewarning
parameter indicates the heat
value (in scale divisions SKT)
for which an imminent %I
limitation is to be detected for
the electrode displayed.
Upper currrent limit is the
maximum programmable set
limit of the current in the
individual electrode
Bosch sensors have been
adjusted to 150 mV / kA.
When using third-party
sensors, the appropriate
transmission ratio can be
programmed using the For details on the
Toroid sensitivity parameter measuring range,
see the next sheet

Electrode Set-Up

Electrode Set-Up
Transformer type. When a pre-
defined transformer is selected,
this automatically selects the
transformer ratio, and the diode
type, If the transformer type is
unknown, then you must
program the diode type and
nominal current.
The Diode
supervision/monitoring
parameter may be used to
deactivate diode monitoring
(secondary diodes of the
welding transformer).
The computational emulation
of the welding diode
temperature determines
whether the junction
temperature is rising to more
than 150°C, the switch off
temp can be programmed from
this parameter
Actual welding diode temp
Actual Mains supply Voltage

Electrode Set-Up
For the calibration

procedures see next
few slides.

Power Unit Set-up
Power unit type,

Medium frequency
Inverter 6000 series
Timer type:-
Software / Firmware
Version:-

Diagnosis User-Diagnostics I/O
Start signal;
this is a signal sent from
the robot, to initiate the
start of a weld sequence
depending on the
program- /spotselection.

Acknowledge tip dress;

after a Tip Dress request
is output from the timer, it
is acknowledged by a
response from the PLC
only when the robot is in
the tip dresser.
Typically there are

specific weld programs
associated with tip
dressing.

Ready Weld timer: the

status of the weld timer
is healthy and the timer
is ready to weld, this
signal stays Hi unless a
fault has occurred
Weld process error:
this signal only goes hi
when a weld fault has
occurred, it can be
reset via input 04, 05 or
06
Weld ON: this shows
the status of the
external and internal
weld on, if both are hi
then current can be
passed

Diagnosis Simulate start
Starting the weld from the

timer.
Press the Diagnostic
Button
Select Simulate Start
Select the Program you
wish to fire.
At the position
Start with Ignition
click once in the “On” tab
The timer will now execute
a weld

Diagnosis Timer information

Diagnosis Last Weld
This page gives

you all information
about the last
weld sequence.

Plant Layout

Plant Layout

Plant Layout
According to the status

chart on the previous
page, what is the
condition of the timers
on the right …?
1. Error state pending,

i.e. control fault
2. End of stepper
3. Offline
Click on the Timer icon will
redirect you to the
timer information page

Login
If you want to log in, or change user,

select the change user icon, or press
F12. Select your username from the
drop down menu and enter your
password

Compare
It is possible to compare data

from one timer to another, or
even to a backup stored on
the hard drive.
The data compared will be
displayed under the titles
here.
Then click Compare

Compare
The number and

type of differences
are then listed.
To view them select

Detail view
Please wait while the

data is compiled

Compare Details

Protocols
You can view the

protocols from the
following sub titles.
Error Protocols
Weld fault Protocols
Data Change
Protocols
Weld current
Protocols
Each one will give
you information about
an event, that has
occurred.

Protocols
You can also select

specific dates to view.
Dependent on the size
of the database, you
can have between
50,000 and 250,000
entries in the protocol
database

Data Change Protocols
Each entry will give

you information
Date / Time
Timer name
Name of parameter
Program Number
Old data
New data
Name of user who
has changed the data
Any comments
entered by the user at
the time of the change

Data Change Protocols
Weld current
protocols are
activated from the
Timer reference
page on start up.
If this option is
NOT selected this
page and the UIR
Monitoring page
will not show any
data.

Overview
The overview page is very useful for

quickly finding out the status of all the
programs at a glance
Select the button on the right and side
and the active programs for your
selection will appear in pink
Error table
Access to the fault table can also be via the F3

function key.
If more information is required for the actual fault,
double click the error description, and more detailed
information will appear.
If still more information is required, click the help
page

Error table
The help page will

appear with a complete
description on the fault,
and a possible remedy.
The Error page is also
used to display status
messages.

Pre-Warning F2
To Access the Pre-

Warning page, click on the
pre-warning Icon or press
the short cut key F2
F2
The information held on this page,
can be critical for
identifying
1. Wear on the caps
2. Number of remaining parts
3. Electrode status,
1. Green : - healthy

Pre-Warning F2
To Access the Pre-

F2
can be critical for identifying
1. Wear on the caps
2. Orange: - Tip dress
required

Pre-Warning F2
To Access the Pre-

F2
1. Wear on the caps
required
3. Yellow: - Prewarning
active

Pre-Warning F2
To Access the Pre-Warning

page, click on the pre-
warning Icon or press the
short cut key F2
F2
1. Wear on the caps
required
3. Yellow: - Prewarning
active
4. Red: - End of stepper
life
Correction
These are the default

correction figures that are
displayed on the actual
correction page.
If these parameters are not
programmed , then the
correction parameters can
not be utilised.
So limits need to be set.

Correction
The limits set on the

previous page can
be seen here, (P) is
for this specific
program.
(E) Is for the
complete electrode

Force Calibration For Welding Guns

Force Calibration
Please select the correct timer,

from the drop down menu
Select the calibration routines. These

can found on the Electrode Page
Ensure that the Transformer Type,

and Upper current limit are set
correctly
To access Force Calibration

Press the Force Calibration Key

Force Calibration
1) Type here the upper

and lower pressure 3) Select here the
limits for the calibration Program you wish to use
routine ( ensure that for the calibration
you are not in the force routine. You should
limitation) select a program that is
associated with the
The lower limit should relevant electrode you
be set to around 20% wish to calibrate
to allow for accurate
pressure for tip Dress
Routines.
The KN display is only

2) If you want to used with Servo Guns.
change the values, 4) Press the OK
place a tick in the box button to enter the
before you type in the next screen
new values. The
changes will then be
stored for the next time
the routine is entered.
Force Calibration
5) As this screen appears

you should hear the
proportional valve either
pressurise or exhaust to
the upper limit value set in
the previous screen.
6) You should now
manually close the Gun
onto the force meter.
7) Enter the read value
into the upper box.
8) To proceed press Enter
on your PC this enters the
upper limit actual value
into the timer.
9) open the gun

Force Calibration
As Enter is pressed you should

hear the Parker Proportional valve
exhaust to the lower limit set on the
previous screen.
10) Again close the Gun onto the
force meter.
11) Enter the read value into the
lower box and press the Enter key
on your PC
•As a rule: the upper and lower value must be in the
This enters the lower limit actual
operating range of the gun !
value into the timer.
12) As the OK button is pressed an

information point appears showing
the value of the now calibrated
Max. Pressure.
If this is ok. for your gun =>
Press OK to Accept this.
13) As the OK button is pressed an

information point is displayed.
Press OK to accept this. 93
Force Calibration
14) You should now return to the

Sequence page and close the
Gun on the force meter to test the
Programmed Pressure set in the
Base Pressure Value.
Please note:- check the I/O

page to see which program
is being activated.
The pressure in this program
Will be output to the prop valve.

Force Calibration
15) The calibration routine has set the

figures shown .
If after adjustment the measured
values are found to be out of range
another Force Calibration routine
should be carried out.

Current Calibration For Welding Guns

Current Calibration
Preparation
Ensure that the following
settings are made
In the General Tab the
Current Measurement
Mode should be set
correctly.
1) If you have a
secondary toriod
attached to the gun arm
or in the transformer,
then secondary should
be selected.
If not, then primary
should be selected.

Current Calibration
2) Select the calibration routines

which are located on the Electrode
Page
3) Ensure that the Transformer
Type, and Upper current limit are
set correctly
4) Ensure that the Diodes

settings are as follows
5) To access Current Scaling

Press the Current Scaling Key

Current Calibration
6) Type here the upper

and lower heat limits for 8) Select here the
the calibration routine Program you wish to use
( As a rule the upper for the calibration
limit should be 20 more routine. You should
than the value of the select a program that is
lower limit) associated with the
relevant electrode you
wish to calibrate.
7) If you want to
change the values,
place a tick in the box
before you type in the 9) Press the OK
new values. The button to enter the
changes will then be next screen
stored for the next time
the routine is entered.
Current Calibration
10) You should now

place a calibrated DC
Current meter over
the secondary of the
Gun.
11) Ensure the gun

head is closed before
you start the weld.
12) Press the Start

Wld button to perform
a short circuit weld

Current Calibration
13) Read the recorded

value from the Current
Meter and enter it into
the Upper Heat
Measured Current box
as shown
14) Press the Enter Key
and a “1” appears at the
side of the box indicating
that the first reading
attempt has been carried
out and the data has
been sent to the timer.
15) Again press the Start
another Short Circuit
Weld and repeat the
steps above. This time
when the Enter Key is
pressed a “2” appears
indicating the second
attempt.
Current Calibration
16/ Now press the continue

key to proceed to the lower
heat limit calibration routine
17/ Again press the Start

another Short Circuit Weld.

Current Calibration
18) Read the recorded

value from the Current
Meter and enter it into
the Lower Heat
Measured Current box
as shown.
19) Press the Enter Key
and a “1” appears at the
side of the box indicating
that the first reading
attempt has been carried
out and the data has
been sent to the timer.
20) Again press the Start
another Short Circuit
Weld and repeat the
steps above. This time
when the Enter Key is
pressed a “2” appears
indicating the second
attempt.
Current Calibration
21) Now press the continue

key to exit the Current
Calibration Routine
22) When the Continue Key

is Pressed an Information
point appears that shows the
new calibrated Toroid Sens.
23) At this point the
Secondary of the Gun can
be opened and you can
proceed with OK

Current Calibration
24) You should now return to the

Sequence page and manually close the
Gun. The Current meter should
Still be in place to test the
Programmed Current set in the
Weld 2 Heat Value.
You can either fire the Short circuit

Weld from the control panel or fire
the sequence with the bos6000
Software by using the procedure on
the next page.

Bos6000 Set-Up, Heat Stepper Curves
Heat stepper curves

can be accessed via
the setup icon.
Several curves are
standard, they can be
selected by the curve
number.
You can also create

your own curve, by
dragging the line into
the required position or
by typing the required
figure directly into the
specific box

Bos6000 Set-Up Continued
Tip dress curves, as with

heat stepper curves are
selectable, or can be
created.
Communications page
shows confirmation of
the Ethernet address,
with the subnet mask.
With error reference page, you have

the ability to program the severity of
the fault into a warning if required. A
fault will inhibit the weld from starting,
A warning will not inhibit the weld
Backing up ..!
From any page the drop

down menu should be
visible,
Select Edit, and then
backup
Or Ctrl + B
Once selected , the

next option is to pick
which Timer or Timers
are to backed up.
By clicking on the top
box, all timers will be
selected, or individual
timers can be selected
by clicking on the box
adjacent to the timer
name
The backup path and folder is located here.
An alternative can be selected by selecting the … button,
and choosing a new location
Electric Drives and Controls When ready press 108
OK all rights relating to copying, transmission and dissemination.
We also retain sole power of disposal, including
Backing up ..!
The status of each timer

can be seen as the backup
is proceeding

Backing up ..!

Restoring Data….
1. From the next page,

you have to select
which backup needs to
be restored, select the
browse key
1. From the Timer

reference page, select
the Restore Button
Restoring Data….
2. Find the backup file

that will be restored.
Note: this will be a zip
file.
Then select open
Restoring Data….
3. Select OK to start the

restore process.

Restoring Data….
4. With the next screen

you have a chance to
review the file data you
are restoring, you can
also see what is already
in the timer, Select OK
to start restoring the
data back into the
database

Restoring Data….
5. The data is now

being sent to the
database,
after a short while, you

will get notification of
completion
7. Click Continue to
complete the
restore function
Help page F1
The Help page can be

accessed by pressing the F1
function key on your
keyboard, or by clicking on
the Help menu.
If you have a specific query,

1st highlight the specific
parameter, then press the
F1 key.
F1

Help page F1
The Help page can be

accessed by pressing the F1
function key on your
keyboard, or by clicking on
the Help menu.
If you have a specific query,

1st highlight the specific
parameter, then press the
F1 key.
F1
The help page that now

appears will be relevant to
the parameter that you
have high lighted

How to extract spatter data from the BOS6000
software
Within the BOS6000 software is a Spot / Expulsion overview page.

This can show the user an over view of the spatter that exists on a complete
line PC, or on an individual timer, thereby assisting in spatter detection and
subsequent removal.
This page can be exported as a text file and then imported into excel.
Please note, this is only available on software release V1.23.0 and later.
Data can be shown in program specific or spot number specific
If you wish to view the data with the spot table an additional requirement is
to ensure the spot table has been extracted from the timer first. See the
next few slides for details on how to extract the spot table.
118
How to extract the spot table from the BOS6000
software
Ensure that before

you extract the
spatter data, the spot
table has been
extracted. Click on
add
119
software
Select Spot Table <-

Timer.
120
software
The spot table then

be displayed.
121
software
Within the BOS6000.

Drop down menu,
Function.
Spot / Expulsion
Overview (Ctrl+F3)
122
software
This screen will be shown.
Select the configuration of the data,
Spot name or program No
Select a date and time from the drop
down menu, this will be the start of
the data to be extrapolated.
Select a date and time from the drop
down menu, this will be the end of the
data to be extrapolated
If you wish all programs or spots to
shown regardless of the expulsion
status tick the box
Select update to display the data

software
Data is displayed and

can be sorted according
to your requirements via
the headings at the top
of the page.
This information can be
exported, and displayed
in excel for further
diagnosis.
The %expulsion data is
calculated and displayed
graphically as well as
numerically

Sheet Thickness Calculation
Requirements for sheet Thickness Calculation:
Settings in BOSKonfigurationtool :
-Select start comment column
- Select number of columns
for sheet thickness calculation.
The output of sheet thickness

Is done in units of 0,1mm

For 4 of these programs / Spots, the sheet thickness is given in the 1. and 2.comment .
Valid inputs are integer numbers or numbers with ‘,’ and following text

Start the sheet Thickness calculation,

Best with activated log.
Please check the file sheetThickness.txt

In the correct subdirectory for details

Please check
the operation
for different
Program
selections.
The output of sheet thickness

Is done in units of 0,1mm 128
BOS6000 UIR Training
Bosch Rexroth
PSQ 6000
UIR Adaptive System
Training

Function of the UI Regulator
 Process Parameters used:
1.) Primary OR Secondary current
AND
Current
2.) Voltage drop on electrodes
= Secondary voltage at gun arms
Secondary
Voltage
=> Dynamic resistance during weld

is calculated from the process parameters, i(t)
current and voltage.
=> Energy balance of weld spot r(t)
is calculated.
Current / Resistance
Curves

Electrode Voltage Tap
UI Current
Regulator Regulator
Reference Command
Curve Current and
Time
Actual Current Value

UIR Component Parts
Regulator Board
XQR
Software
BOS 6000
Sensor Cable

UIR: Installation
 Connect the voltage tap as close as possible to the gun tips wherever
practicable.
Goal: minimise losses of feedback signal, due to contact resistance.
 Install sensor cables apart from secondary power cables, possibly

along water tubes.
 Sensor cable:
Max. length 100m twisted, screened 2 x 0.75²
Max. open length w/o screening and twisting: appr. 1m
 When intermediate connectors are used, the screen must be

connected. The screen can be grounded on the UI regulator board or
on the PE bar of the cabinet.

Operation of the UI Regulator
Produce
a quality weld
Store
current / voltage / resistance curves
Monitoring Reference Regulation

Compare the actual by variation of current
curve with the reference and weld time

Current
Voltage
Act. Res
Ref. Res

Operation of UI Regulator
1. Weld in KSR mode

Optimize the parameters: current, time and force.
Eliminate spatter and ensure good weld integrity.
2. Record Reference Resistance Curve
The resistance curve is generated from the process parameters.
It will be used as reference for the following welds.
3. Switch the UI regulator ON
Activate regulation for all relevant programmes.
4. Weld with UI regulation and monitor the process
Ensure that the weld process is stable and set monitoring limits
for UIP and PSF.

UIR: Compensation of Disturbances
Shunting Variation of coating

Bad fitting of sheets Glue
ΔF
Bad tips
3-sheet Variation of Variation of force
welding sheet
thickness 137
BOS6000 UIR : General Parameters
Programming
Single software package for the programming of weld parameters and UIR
Global settings for

all electrodes
and programs
“Robot“ mode to be
selected for
automatic
applications

BOS6000 UIR: Program Parameters
Settings for
Individual
programmes

BOS6000 UIR: Program Parameters
Monitoring
Measurement Regulation

BOS6000 UIR: Measurement Parameters
Parameter for
Weld & expulsion detection of
counters expulsion
% decrease of R
Measurement

BOS6000 UIR: Regulation Parameters
Time in weld
sequence
when full regulation
will
become active
Indication that
regulation has been
Limits for welding activated for this
current program
Activation of weld time

prolongation Regulation

BOS6000 UIR: Monitoring Parameters
Activation of
monitoring for this
programme
Indication that
Monitoring
monitoring has
been activated for
this programme

The monitoring
function can be
activated separately
for each of the
supervision
parameters.
Depending upon the

process it may be
appropriate to monitor
different variables.
Normally Process
Stability and UIP are
the best to use.

Upper Tol.
When a monitored
parameter has been Desired Value
activated, the actual Cond. Tol.
data points for the Lower Tol.
parameter are
displayed with the
desired value and
tolerance bands

Setting of Weld Parameters with UIR
Weld Splash Zone
Splash Limit
kA Good Weld Integrity
Weld Failure Limit
Weld Failure Zone

Weld Splash Zone
Splash Limit
Good weld parameters - KSR
kA
Good weld parameters - UIR
Weld Failure Limit
Weld Failure Zone

Weld Splash Zone
Splash Limit
KSR parameters with current
kA increase due to heat stepper.
NO splash
Weld Failure Limit
Weld Failure Zone

Weld Splash Zone
Splash Limit
KSR parameters in UIR
kA Regulation, with weld splash
Weld Failure Limit
Weld Failure Zone

Weld Splash Zone
Splash Limit
Weld parameters in UIR
kA Regulation with NO splash
Weld Failure Limit
Weld Failure Zone

Protocol of Field Test (2006)
Original parameters,
very hot, to allow for
weld errors, lot of
spatter
New parameters not in

UIR regulation
Manual station with a

large variation of gun
angle due to human
operation, thus
creating a reaction
from the UIR Controller
to maintain a good
weld

UIR: Viewing UIR Curves
The
“Diagnosis”
window and
When a weld the “PSQ” tab
has been need to be
created with selected to be
“Measuring” able to see the
activated, the UIR curves
resultant curves
will be displayed

By activating the
“Stop” function, it is
possible to select
previous welds by
use of the scroll
buttons.

The generated curves

can also be viewed
from the
“Programming” and
“UIR Reference”
screen.
The curves do not

appear automatically
and will have to be
retrieved from the timer
via the “Actual curve<-
Timer” button.

UIR: Generating Reference Curves
Once the welds have been

fully optimised in KSR
mode, it is then possible to
generate reference curves
for the necessary
programmes.
Select the “Setup” and “UI
Setup” tabs followed by the
“Recording Mode” button.

Select the timer that

the resistance Activate the
curves are to be recording mode by
recorded for. pressing the “Start
recording” button.

Record the welds for

at least one complete
tip dress cycle. At
least 10 curves are
recommended.
Once the necessary

number of curves has
been recorded, the
recording can be
stopped.

If the welding is stable

and the resistance
curve shape is uniform
an average curve can
be generated for the
selected programme.

The relevant curve

can be selected until
it is highlighted in
red.
Any curves that are not
acceptable can be
deleted.
The actual curve can

then be deleted.

Curves with
detected spatter
can be deleted
As well as those that

were created with a
heat stepping value It is also possible to
above a certain limit. delete a selection
of curves at one
time

The average curve is

highlighted in red, with the
minimum and maximum
curves also being
displayed.
If the displayed average

curve is acceptable it can
be sent to the timer as a
reference for the selected
programme.
Generated
reference curves
can also be saved
to the PC.

UIR: Viewing Reference Curves
Once a reference curve

has been generated and
sent to the timer, it can be
viewed using the “UIR
Reference” screen.
Generated
reference curves
can also be saved
to the PC.

UIR: Switching to Regulation
When the reference

curve has been sent to
the timer, the Regulation
and Monitoring can be
activated for the
selected programme.
The displayed parameters

should be set as defaults
for all programmes

Summary: Generation of Reference Curves
 Dress tips or change tips

 Condition tips by welding approx. 20 spots
 Activate Measurement (global and program-related)
 In UI Setup, Recording Mode, weld part spot by spot without spatters and
store the actual curves
 Evaluate the spot quality; if correct, load the average curve as a reference
 Set max. prolongation of weld time (e.g. 100%)
 Set limits of current variation (e.g. +15% / -5%)
 Define reaction on spatter
 Activate Regulation (global and program-related)

UIR: Reference Curves
Adaptive Regulation is active

from the first msec.
The shape of the resistance

curves differs quite a lot due to:
• different materials used
• different thicknesses
• different coatings
• etc. resistance curve
with good
dynamic
Important: A good reference
curve is determined by good
weld quality
and not by the shape.

UIR: Monitoring Parameters
Set the
Repetition
On the UIR Factor to 1
Monitoring screen,
set the monitoring
to ON for the
Current, UIP and
Process Stability
(PSF) and set the
parameters as
initial starting
values.

With the current

monitoring selected,
select a stable weld
that was carried out
without regulation and
send this value to the
timer as the reference
value for all
parameters.

If more than 1 consecutive

value lies between the
conditional and lower limit
then a repeat fault will be
produced.
The displayed fault

indicates that there has
been a repeat error for
process supervision.

• Resistance - the value displayed is the maximum resistance achieved during the weld.
• Heat, = Power = Voltage (V)* Current (I)

The figure displayed is the average power for the duration of the weld
• Energy = Heat * Time, (V*I)*T

The figure displayed is the Energy for the duration of the weld
• Voltage - the displayed value is the average over the duration of the weld.
• Current - the displayed value is the average over the duration of the weld.
• Phase Angle - the displayed value is the actual value required to achieve the
demanded current

• Process Stability
The resultant figure is a calculation based on Voltage, Current & the
extended weld time.
The displayed value relates to differences between the reference curve
and the actual curve. The greater the difference, the further from 100%
the resulting value.
The value for Process Stability will always be <=100
• UIP
This is a quality index based on Resistance, Voltage, Current and Time.
A comparison is done after the weld between the reference curve and the
actual curve. The result is nominally in the region of 100, although a
figure up to 200 is not uncommon, and is also acceptable.
If the result is significantly less than 100, then it could be possible that
the weld may be undersize or loose.

UIR: Reaction of the UIR Regulator
The UI regulator compares

the values for the actual
and reference resistance
every msec.
If there are differences
then the regulator adjusts
the weld current
accordingly.
Increase in The current will be
current to adjusted up to the limits
compensate set in the UIR
for the programming page.
reduced
resistance

UIR: Reaction of the UIR Regulator
When the actual

resistance is greater than
the reference value, the
weld current will be
reduced.
At the end of the

Reduction in Current programmed weld time
( Programmed the regulator compares
value is 7.4kA) the weld energy with the
energy for the reference
Weld time weld and prolongates the
extension weld time accordingly

Diagnosis UIR

Diagnosis UIR

UIR: Reference Gun Resistance
• Restart BOS6000 with Access-level „System“

• Open the page Programming \ UIR Reference
Read the actual

curve from Timer
Press the button

„Gun resistance“.
Then use a special

program for a short
circuit test of the gun.

Notice the characteristic of this weld !

There is no change in resistance !!

When pressing the button

„Resistance to Gun resistance“
the resistance (here the 97uOhm)
is copied into the parameter shown.
Starting from now, in every reference

curve the „reference Gun resistance“
is taken as parameter for this reference
curve.
Lateron, change the

test gun resistance
manually to 90 uOhm
and send Data to timer


UIR: Fault Conditions
Measuring Circuit Error - If

the voltage tap is not
correctly installed then this
error will occur.

NOTE:
If problems are experienced
with the UIR measuring
circuit, then by switching the
Global parameter for UIR
Measuring to OFF, the
system is deactivated for all
programmes.
In this case the programmed
KSR current gets active
and
KSR current monitoring
limits will become active
for all programmes.
OFF to be
selected
Important:
To use this feature correctly,
UIR and KSR parameters
must be optimised to give
good weld quality.
PSQ Maximum Weld Time

Exceeded – This error
occurs if the regulator
attempts to extend the
weld time past the
prolongation limit that has
been set.

Thank You
Questions and Answers


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BOS6000 & UIR Adaptive Weld Control

Training Package 2010

Version 1.36.0 Aug 2010

Electric Drives and Controls 1

UIR Regulation system Pg 129

Electric Drives and Controls 4

Setting of weld parameter for UIR Pg 146

Electric Drives and Controls 5

Electric Drives and Controls 7

Rectification Machine Interface,

Secondary coil (KSR)

Typical ouput 5-12v DC

Electric Drives and Controls 9

Gun close open

SQZ WLD HLD

Electric Drives and Controls 12

4.) Signal lamps

5.) Main Switch

8.) 2x Main Switch

Electric Drives and Controls 13

Roboter bus system (optical Interbus)

24VDC Supply Input

Bosch Rexroth Welding Control (timer)

Electric Drives and Controls 14

I/O Card slot

Electric Drives and Controls 15

Electric Drives and Controls 18

Electric Drives and Controls 19

Industry Standard is 150mV / kA. This

A normally closed contact in the

Electric Drives and Controls 21

Wiring schedule for the Serial port

Electric Drives and Controls 22

When connecting via an Ethernet link, please ensure

If you do not have this icon present, select the

Electric Drives and Controls 23

Select, Use the following IP Address then OK

Setting the IP Address Enter an IP Address and subnet mask then OK

Electric Drives and Controls 24

BOS6000 Software Familiarisation

Electric Drives and Controls 25

Electric Drives and Controls 26

2. Add the timer name

Monitor the Status and

Monitor the Status and Description

The raised tab indicates the

Nearly all functions/pages

A single click will select the

Electric Drives and Controls 29

Error Table Plant layout

The BOS6000 software

The BOS6000 software

Electric Drives and Controls 31

By selecting individual tabs within the

Dependent on the timer status, you can

You can also see at a glance if the weld

For PSI6000 inverters the

PST6000 timers are

Electric Drives and Controls 33