May 2023 Volume 5

AUTOMATION

Verify End of ArmTooling Setup If your robot has tooling that requires a setup for a job change, how do you know this has been accomplished correctly before starting operation? For example, let’s say a mechanical gripper has two finger sets which cover the range of part sizes to be handled. We will name them Set A and Set B. Set A covers the smaller diameter part family and Set B covers the larger diameter parts. A job change should include messages written to an HMI, or in the absence of an HMI, the robot teach pendant can be used. The messaging should show the operator how to identify and mount the correct finger set. Also, the automation should verify the correct finger set has been

installed prior to moving into automatic operation. This can be accomplished by “showing” the changeover details to an appropriate sensor. For example - program the robot to show the finger to a proximity sensor that detects an identification feature on each finger that is unique to the finger set. For automatic tool changers, be sure to code the tool so that the robot can identify which tool is on board via electrical signals in the tool mount disk. These tool verification programs only need to run at the beginning of the job. During the campaign, it is a good idea to verify open/closed sensors and part presences sensors are functioning correctly. This is another easy housekeeping program to create and embed in the mainline program.

Verify correct fingers are installed prior to automatic operation.

this. For example - a power outage knocks the cell offline for several minutes and the billet has cooled to the point it has to be discarded. Think about these “what-if ” scenarios as you design the software. Creating sub-routine robot programs so that it is easy to jump between tasks is highly recommended. Have a program to pick a billet, load the press, discard cold parts, etc. Rather than having a 300 step robot program, which is hard to navigate and troubleshoot, it is easier to create 10 short programs that do only one task. Giving the operator easy to access controls that allows them to stop

Unexpected Conditions and How to Deal withThem If you already have robots, you know that some skill is involved in jogging the robot safely and effectively, especially in close quarters. For instance, trying to jog a robot through the side window of a press is nearly impossible unless you know how to select the correct coordinate system and set the jog speed. The reader will ask why would I need to do this during normal operation? It is not a normal operation that requires this kind of intervention, but rather unexpected conditions that can require

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