This topic will explain how many of the optional Simple Connect devices and software options function. The information in this article is intended to help with general interaction and troubleshooting.
These devices will be discussed in detail:
- Wire Brake
- Operator Station
- Tip Change Box
- Status Beacon
- Torch Cleaner / Reamer
Wire Brake
This implementation allows welding torches with a wire brake to be controlled through an external air manifold with unique valves for each welder. Logic is provided so the brake engagement is a specified action via an output, not engaging automatically at the end of every weld. This allows the users to engage the brake only when needed (i.e. TouchSensing). This prevents change of activation frequently; for example, when starting or stopping a weld sequence on the same part.
This approach prevents unneeded wear on the pneumatic valves and delay weld starting sequences.
Additional information about the Wire Brake can be found at this article:
Operator Station
Multiple permutations of Operator Stations are available from Yaskawa as pedestal mount solutions. These variations include different combinations of buttons and controls depending on the application needs. For specific data about your operator station, consult the system diagram available with your solution.
The E-Stop button is always hard-wired into a dedicated cable circuit. In some cells, like the AW6000, this connects to the M12 board described in section section 6.2.2 “RM2 Positioner Version”. In other cases, the cable can be run directly back to the robot controller and wired in as its own dedicated pigtail.
Other push buttons and indicators are converted to data on the EtherNet/IP network. The enclosure of the operator station houses one or more module to bring digital I/O signals into EtherNet/IP network.
All operator stations include these controls as standard:
- SERVO ON – push button and indicator
- ROBOT HOLD – push button
- ALARM / RESET – push button and indicator
- CYCLE START / CYCLE LATCHED – push button and indicator
- START – push button
- EMERGENCY STOP - push button and indicator
These button and indicator types are added in various permutations to
produce different variants of operator stations:
- POSITIONER AUTO/MANUAL – mode selector switch
- REV / HOME / FWD – 3 mode joystick
- LIGHT CURTAIN RESET – push button and indicator
- THUMBSWHEEL SWITCH – 3-digit dial
- CYCLE DOOR – push button
When a Thumbwheel Switch (TWS) is included in the operator station, this allows the operator to select a 3-digit number and send it to the robot controller. Typically, this is used to quickly convert between parts, schedules, or programs that the robot jobs will call. Operator stations can be configured with one, two, or no TWS devices. The Knowledge Center article that follows explains how the data in the TWS can be utilized, evaluated, and read in the robot controller.
Additional information on Thumbwheel Switches can be found here:
Tip Change Box
One or more Tip Change Boxes can be added to a system to enable operators access to the robot’s torch to change a tip without entering the cell enclosure.
Each enclosure includes buttons for the operator to start the process, advance wire, and indicate completion. An Emergency Stop button is also available. The robot is programmed to approach the window and shut down servo power so that the tip of the weld torch can be changed at preprogrammed intervals. Upon completion, the operator closes the door, and the system resumes operation safely after pressing the appropriate button.
The Tip Change Box includes two dual channel safety elements:
- The E-Stop button which can stop the system at any time or prevent start-up.
- The swing open door guarded by a dual channel switch which prevents the system from enabling servo power to the robotic system which the door is open.
Additional information on the Tip Change Box with Remote Mode can be found here:
Status Beacon
There are two types of status beacons developed for the Simple Connect product line and use:
- Basic – with 7 Color LED and Horn
- Advance – with 7 Color LED and Speaker / Voice Alerts
One or more of these units can be installed on the ArcWorld system. Logic in the robotic ladder allows one color to display on the LED at a time. Prioritization is implemented such that alarms are displayed before warnings.
Each status beacon comes with a “Quick Card” explaining how the colors are displayed and what they mean. This is expected to be mounted on the fence or equipment near the status beacon:
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Details on the operation and tips for this device type are described in the following Knowledge Center articles.
Additional information on the Muting the Beacon can be found here:
Additional information on the Cyan Indicator of the Beacon can be found here:
Torch Cleaner / Reamer
This stand-alone device uses a pneumatic motor with a reamer to clean the torch nozzle. There is no logic or programming within the Turck block. All logic is handled by the concurrent I/O ladder and robot jobs.
Torch Cleaner with ToolSight
A ToolSight module can be added to most Torch Cleaners, making a compact solution with the added benefit of utilizing the existing riser/stand and existing cable system. In the case where the Reamer is wired to the EtherNet/IP network by Simple Connect cabling, the ToolSight signals will also communicate back to the robot controller by EtherNet/IP.
ToolSight is a non-contact, dual fiber-optic gauge designed to automatically detect worn contact tips, excessive wire cast, and torch alignment problems during production. ToolSight can be used to quickly check the robot’s Tool Control Point (TCP) online, verify it is within acceptable limits, and calculate tool offsets to correct the TCP. ToolSight can be used as a GO/NO GO diagnostic tool, or it can be set up to automatically update every relative job that uses this TCP. Before the TCP is modified, the standard software will prompt the operator to perform a visual inspection of the contact tip.The ToolSight package includes the accessory gauge, the robot jobs, Relative Job software, and an instruction manual. For the standard ToolSight, a Torch Alignment Pointer is provided so that the operator can visually compare the TCP with a fixed point and slide a collar into the nozzle over the contact tip. When used with Simple
Connect, the ToolSight sensor operates across Ethernet/IP. The sensor plugs directly into the existing reamer interface and does not require any additional cabling between the reamer stand or within the robot controller. The Toolsight jobs have been adjusted to compensate for the EtherNet/IP searching (search speeds have been slowed to ensure maximum repeatability) and confirm for consistent variable usage.
NOTE - When the ToolSight option is enabled, the RPI setting for communication over EtherNet/IP is reduced to 5ms, this allows a faster refresh time and should increase the response data the robot controller reads relative to other devices on the network.
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