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Chrysler’s Robotics Group Applications Standards For

Controlled Robots For Use On CUSW North America Projects

If you received this document by means other than a direct E-Mail from Chrysler AAME Robotics Group, you are not on the distribution list and you will not receive future updates. It is the user’s responsibility to obtain the latest updates to this document.

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TABLE OF CONTENTS RELEASE REVISION AND COMMENTS PAGE...................................................................................................... 5 PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT OF ROBOT ............................................................ 7 ROBOTIC BY-PASS CONCEPT ............................................................................................................................... 7 TEACH PENDANT USER KEY ASSIGNMENT ........................................................................................................ 7 USE OF PULSED OUTPUTS .................................................................................................................................... 7 USE OF ROBOT PROGRAM SPACE CHECK ........................................................................................................ 7 COORDINATED MOTION OF HORIZONTAL AXIS ................................................................................................. 7 ROBOT DRESS REQUIREMENTS........................................................................................................................... 7 SEALER STYLE NUMBERS..................................................................................................................................... 7 SEALER SYSTEM CALIBRATION TO ROBOT ANALOG OUTPUT ...................................................................... 8 SEALER SCHEDULES ............................................................................................................................................. 8 NETWORK ADDRESSES ......................................................................................................................................... 8 FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC .................................................................. 8 ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC)............................................................................................ 9 ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT).............................................................................................. 13 ROBOT IO MAP ASSIGNMENTS ........................................................................................................................... 18 ROBOT BIT MAP .................................................................................................................................................... 19 ROBOT APPLICATION ERROR TIMING ............................................................................................................... 41 ROBOT APPLICATION ERRORS .......................................................................................................................... 42 PLC LOGIC REFERENCE ...................................................................................................................................... 48 ROBOT PROGRAM NAMING ................................................................................................................................. 49 ROBOT INTERFERENCE ZONES.......................................................................................................................... 50 INTERFERENCE ZONE EXAMPLE 1 ............................................................................................................................ 51 INTERFERENCE ZONE EXAMPLE 2 ............................................................................................................................ 52 INTERFERENCE ZONE EXAMPLE 3.................................................................................................................... 53 PLC / ROBOT TIMING DIAGRAMS........................................................................................................................ 54 REGISTER USAGE ................................................................................................................................................. 57 NUMERICAL REGISTER USAGE .......................................................................................................................... 57 POSITION REGISTER USAGE ............................................................................................................................... 59 USER ALARMS ....................................................................................................................................................... 61

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REFERENCE POSITION USAGE ........................................................................................................................... 62 INTERCONNECTS .................................................................................................................................................. 63 MACROS ................................................................................................................................................................. 64 FLOW CHART EXAMPLES .................................................................................................................................... 66 MATERIAL HANDLING .............................................................................................................................................. 67 DISPENSE............................................................................................................................................................... 72 SPOT W ELDING ...................................................................................................................................................... 73 STUD W ELDING ...................................................................................................................................................... 75 TIP CHANGE (STYLE #3) ......................................................................................................................................... 76 PURGE (STYLE #4) ................................................................................................................................................. 77 TIP BURN IN (STYLE #5).......................................................................................................................................... 78 SERVICE (STYLE #6) ............................................................................................................................................... 79 TIP DRESS GUN 1 (STYLE #7) ................................................................................................................................. 80 TIP DRESS GUN 2 (STYLE #8) ................................................................................................................................. 81 TOOL CHANGE (STYLE #9) ...................................................................................................................................... 82 SET APPLICATION IO (MACRO) ................................................................................................................................ 83 CHECK ATI ERRORS (MACRO) ................................................................................................................................ 84 CHECK TOOL (MACRO) ........................................................................................................................................... 85 DROP TOOL NEST 1 (MACRO) ................................................................................................................................. 86 ENTER ZONE 1 (MACRO)......................................................................................................................................... 88 HOME IO (MACRO) ................................................................................................................................................. 88 MOVE HOME (MACRO) ............................................................................................................................................ 88 MOVE HOME FROM POUNCE (MACRO) .................................................................................................................... 88 PICK TOOL NEST 1 (MACRO) ................................................................................................................................... 89 PROCESS APPLICATION MACROS (SPOT, DISPENSE, STUD) ...................................................................................... 91 PURGE PED GUN (MACRO) ..................................................................................................................................... 94 RESET STEPPER (MACRO) ...................................................................................................................................... 94 TIP BURN IN (MACRO) ............................................................................................................................................. 95 TIP DRESS GUN 1 (MACRO) .................................................................................................................................... 97 TIP DRESS GUN 2 (MACRO) .................................................................................................................................... 98 TIP DRESS PED GUN (MACRO) ................................................................................................................................ 99 TOOL DROP PREPARATION (MACRO) ..................................................................................................................... 100 TOOL PICK PREPARATION (MACRO)....................................................................................................................... 101 TEACH PENDANT LOGIC EXAMPLES ............................................................................................................... 102 MATERIAL HANDLING ............................................................................................................................................ 103 DISPENSE............................................................................................................................................................. 105 SPOT W ELDING .................................................................................................................................................... 106 STUD W ELDING .................................................................................................................................................... 107 TIP CHANGE (STYLE #3) ....................................................................................................................................... 108 PURGE (STYLE #4) ............................................................................................................................................... 108 TIP BURN IN (STYLE #5)........................................................................................................................................ 109 SERVICE PROGRAM (STYLE #6)............................................................................................................................. 109 TIP DRESS GUN 1 (STYLE #7) ............................................................................................................................... 109 TIP DRESS GUN 2 (STYLE #8) ............................................................................................................................... 110 TOOL CHANGE (STYLE #9) .................................................................................................................................... 110 CHECK ATI ERRORS (MACRO) .............................................................................................................................. 111 CHECK TOOL (MACRO) ......................................................................................................................................... 112 DROP TOOL NEST 1 (MACRO) ............................................................................................................................... 113 PICK TOOL NEST 1 (MACRO) ................................................................................................................................. 114 ENTER ZONE 1 (MACRO)....................................................................................................................................... 116 HOME IO (MACRO) ............................................................................................................................................... 116 PROCESS APPLICATION – PED SPOT (MACRO) ....................................................................................................... 117 PROCESS APPLICATION – PED DISPENSE (MACRO) ................................................................................................ 118 PROCESS APPLICATION – PED STUD (MACRO) ....................................................................................................... 119 PURGE PED GUN (MACRO) ................................................................................................................................... 119 RESET STEPPER (MACRO) .................................................................................................................................... 119 TIP BURN IN (MACRO) ........................................................................................................................................... 119 AS OF 1/12/2012 Printed copies are not source controlled

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TIP CHANGE PED GUN (MACRO) ........................................................................................................................... 119 TIP DRESS GUN 1 (MACRO) .................................................................................................................................. 120 TIP DRESS GUN 2 (MACRO) .................................................................................................................................. 120 TIP DRESS PED GUN (MACRO) .............................................................................................................................. 121 TOOL DROP PREPERATION (MACRO) ..................................................................................................................... 122 TOOL PICK PREPERATION (MACRO)....................................................................................................................... 123 The flow charts and sample programs supplied in this document are intended as a basic example and may not include all information required to properly control a robot in all applications. It is the build vendor's responsibility to provide robot programming required for proper system operation. The examples set forth in this document shall be followed. Any deviations will require approval by Chrysler Robot Specialist.

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RELEASE REVISION AND COMMENTS PAGE Release #

Release Date

Rel. 1.0

12/14/10

Rel. 1.1

2/4/11

REL. 1.2

REL1.3

-

Comments Initial Release

Adjusted Rbt/PLC bitmap to eliminate water saver control. DO[99], DI[7], DI[97], DI[98]. Update the Node Allocation – Eliminated the Water Savers, moved to PLC control. Updated Rbt/PLC Node descriptors per the bitmap. Spared out 4 Water Saver Nodes-I/O. Updated Safety I/O Added WaterOff to the bitmap DO[100] Removed reference to WK and WD in robot program naming Spared out DO91, 92, 95, 96 and 100 – Use Group Output [MaintReqBits1-8]. (TipChangeReq, ServiceReq, RbtTPPurgeGun1, RbtTPPurgeGun2, TipDressReq) Added air pressure master node and outputs to PLC DO[91] and [92] Added StepMode output DO[103] Added SignatureChgInd output DO[111] Updated Watersaver App Errors Updated Nordson App Errors to match new configuration Updated Nordson BitMap to match new configuration Added sealer style comment. Added sealer calibration requirement Added sealer schedule programming requirement Swapped air pressure inputs to match tooling Removed repo input bit 4 DI[84] Added General Communication Fault DeviceNet Master App Error [2] Added Low Battery Indicator App Error [4] Removed App Error [127] Dispense 1 Minor Alarm Removed App Error [128] Dispense 1 Communication Fault to Robot Removed App Error [137] Dispense 2 Minor Alarm Removed App Error [138] Dispense 2 Communication Fault to Robot Nordson app errors modifications Added Interference Zone 3 reference Added DO[107] – TipBurnInComp Added AtPurgePos to position register Added Tip Wear Update to Spotweld program Added PartPresent 7-10 on bit map sheet. Updated DI[121] Added RbtClrZone7 & 8 to DO[39], DO[40], Zone(7 & 8)ClrToEnter to DI[39], DI[40] and DO[908] PulseBatteryLow Updated Interconnects list Added IPG_Laser and HighYag Head I/O to nodes 17 and 18 Added LaserEnbld DO[87] and HYagEnbld DO[88] Added LaserEnable1 DI[6] and LaserGuideOn DI[7] Added LaserCut Head and Grinder to nodes 19 – 23 Changed the TipChange burn-in schedule from 58 to 62 per Welding CoC team P. 104. Updated the Nordson bitmaps per the requirements of the tech sealer document. Added DI[98:StartUpPurge] to PLC bitmap per tech requirements. Added DO[95:TipDressReq] to PLC bitmap Updated Interconnect Table Added track lube faults to the application error list Added note indicating responsibility to set IP addresses and Node addresses. Added I/O map for the Precitec unit. Added DI127 Tip Dress Bypass Added DI768-775 and DO768-775 for Mig Weld Reamer Added DI776-783 and DO776-783 for Laser cutting field I/O Update Tip Dress Macro add DI127 TipDressInBypass Added RTU Auto Lube I/O

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PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT OF ROBOT It is an AAME requirement that all Body shop and Assembly robots be capable of running an alignment program. This program will bring the robot into a position which will allow positioning of all axes to check robot alignment. The robot alignment position and path to reach this position must be considered when locating and processing the robot in the cell. Consideration must also be given when dressing out robot cables, hoses, end effectors and junction boxes on the robot arm so these items do not impede the robots ability to move to the alignment position. Where possible, all axes should be aligned at the same time. In cases where cell layout would be affected or additional dress-out or safeties would be required to align all axes simultaneously, multiple alignment positions will be allowed. In addition to alignment program, all OEM‟S must verify that the robot is set to FANUC ROBOTICS factory values for alignment position prior to programming robot.

PROCESS CYCLE TIME REQUIREMENTS It is an AAME requirement that all Body shop and Assembly robots be capable of meeting process cycle time without the presence of robot errors or warnings of any kind. ROBOTIC BY-PASS CONCEPT The Robot By-pass Mode is selected through the HMI screen associated with the specific robot. When in By-pass Mode, the PLC logic should allow the following: In processes which allow a specific robot to be by-passed, (line capable of running without this specific robot with manual or automatic backup capabilities). A. B. C.

Allow the current part or job to transfer out of that station (if the robot is clear). Allow the line to continue to run while the robot is in by-pass and clear of all tooling. Send required back-up information to down stream robot(s) and/or FIS/AVI for downstream manual backup.

In processes which do not allow for the line to run with a specific robot in by-pass. A. B. C.

Allow the current part or job to transfer out of that station (if the robot is clear). Stop further machine cycles if left in by-pass mode. Allow for easy changes to the PLC logic to override item “B” in the event that the plant provides temporary manual back-up for continued production.

Note: Process Engineering, during the Design Phase of a project, will identify robots that can be by-passed while tooling continues to operate.

TEACH PENDANT USER KEY ASSIGNMENT The user definable keys on the robot teach pendants are to remain at FANUC ROBOTICS default settings unless a deviation is submitted by the Requestor and approved by a Chrysler Robotic Group representative.

USE OF PULSED OUTPUTS The use of pulsed outputs requires approval by a Chrysler Robot Specialist.

USE OF ROBOT PROGRAM SPACE CHECK The use of robot program space check requires approval by a Chrysler Robot Specialist.

COORDINATED MOTION OF HORIZONTAL AXIS All robots utilizing a horizontal slide axis shall be setup and programmed using coordinated motion with the other six axes of the robot arm.

ROBOT DRESS REQUIREMENTS FANUC robot dress packages for all spot welding and material handling robots will be supplied for installation. It is the responsibility of the build supplier (robot programmer) to adjust and validate all robot dress packages to meet the dress manufacturer‟s warranty. Robot programs must be considered when configuring the supplied dress package.

SEALER STYLE NUMBERS Sealer styles shall match the value of the robot program number. (i.e. If the sealer robot is executing program #30, the sealer style program shall utilize style #30).

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SEALER SYSTEM CALIBRATION TO ROBOT ANALOG OUTPUT -

It is the robot programmers responsibility to calibrate the Sealer System to the Robot System. Minimum and maximum speeds related to the robot analog output signal to produce required bead sizes must be established and verified at time of programming.

SEALER SCHEDULES -

It is the robot programmers responsibility to populate all sealer schedules with values appropriate for the working programs. All sealer schedules not utilized in a program shall be set to the maximum flow rate available from the sealer system.

NETWORK ADDRESSES -

It is the robot programmers responsibility to set all IP addresses and Node addresses associated with the robot system.

FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC The PLC logic should monitor the following robot DeviceNet outputs. The “Robot Ready” signal should be true to achieve machine automatic but is not required to maintain machine automatic. Proper fault messages should be generated for each associated condition. “Robot Ready” DeviceNet - This signal is true when the following conditions are met: CMDENBL SI[2]=ON CMDENBL SFSPD=ON CMDENBL ENBL=ON CMDENBL $RMT_MASTER=0 CMDENBL No active alarms CMDENBL Not in single step SYSRDY ENBL=ON SYSRDY GRP1 Servo ready SYSRDY GRP2 Servo ready GRP1 Motion enabled GRP2 Motion enabled Spot weld enabled Gun stroke enabled

(OK) (standard operator panel input 2, remote) (OK) (safety speed input signal) (OK) (OK) (no remote device in control of motion) (OK) (OK) (OK) (OK) (OK) (Spotweld only) (OK) (Robot motion group) (OK) (Servo motion group, spotweld only) (OK) (Weld status, welding applications only) (OK) (Gun stroke status, welding applications only)

The following signals are available through DeviceNet and should be displayed as faults or messages when their appropriate state hinders achievement of the tooling system automatic: Robot System Ready for AUTO RobotInAuto RbtReady IOSimulated 20HourRunModeAct Collision Guard Enabled TP Enabled Waiting for TP Input Robot E-Stop Enabled Weld Enabled (Spotweld only) STEP Mode

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ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC) SIGNAL NAME RobotInAuto

ROBOT OUTPUT 1

RobotFaulted WaitForTPInput

2 3

InCycle

4

CollisionDetd

5

IOSimulated WldEnabled

6 7

RobotReady

8

ActiveStyleBit1

9

ActiveStyleBit2 ActiveStyleBit4 ActiveStyleBit8 ActiveStyleBit16 ActiveStyleBit32 ActiveStyleBit64 PrgPaused

10 11 12 13 14 15 16

PrgRunning

17

RobotAtWork

18

WorkComplete

19

20HourRunModeAct

20

MaintReqBit1

21

MaintReqBit2 MaintReqBit4 MaintReqBit8 RobotAtPounce

22 23 24 25

RobotAtService

26

RobotAtHome

27

RobotInTipDress

28

TipDressComplt

29

RdyForTipChg

30

ClearToTransfer

31

WldInPrgrsActiv1

32

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DESCRIPTION This robot output signal is used to inform the PLC that the robot Auto/Teach key switch is the auto position. This robot output signal is used to inform the PLC that the robot is in a faulted state. This robot output signal is used to inform the PLC that a user response is required at the robot teach pendant. This robot output signal is used to inform the PLC that a robot program is executing. This includes Home I/O execution. “InCycle” remains high when the program is paused. This robot output signal is used to inform the PLC that a collision was detected on the robot. This robot output signal is used to inform the PLC that a robot input is simulated. This robot output signal is used to inform the PLC that the weld mode is enabled at the weld controller. This robot output signal is used to inform the PLC that all conditions for robot ready are satisfied. This robot output along with the next six bits, grouped as “Group Outputs”, are used to inform the PLC of the current style active. The group outputs are viewed as the binary bit weight viewed as a decimal value. Reference description: “ActiveStyleBit1” Reference description: “ActiveStyleBit1” Reference description: “ActiveStyleBit1” Reference description: “ActiveStyleBit1” Reference description: “ActiveStyleBit1” Reference description: “ActiveStyleBit1” This robot system output signal “UO[4: Paused]” is used to inform the PLC that the robot program is in a paused condition. Signal is active in Auto and Teach modes. This robot system output signal “UO[3: Program Running]” is used to inform the PLC that the robot program is running. Signal is active in Auto and Teach modes. This robot output signal is used to inform the PLC that the robot has left the pounce position and is in the work portion of the robot program. This robot output signal is used to inform the PLC that the robot has completed the work program. Resets after WorkCompleteAck received from the PLC. This robot output signal is used to inform the PLC that the robot is in 20 hour run mode. This robot output signal along with the next 3 bits, grouped as “Group Outputs” are used to inform the PLC to execute the desired maintenance program 1-9. The group outputs are viewed as the binary bit weight viewed as a decimal value. Reference description: “MaintReqBit1” Reference description: “MaintReqBit1” Reference description: “MaintReqBit1” This robot output signal is used to inform the PLC that the robot is at the pounce position. (Output set by user program) This robot output signal is used to inform the PLC that the robot is at the service position. This robot output signal is used to inform the PLC that the robot is at the home position. This robot output signal is used to inform the PLC that the robot is at the tip dress position. This robot output signal is used to inform the PLC that the tip dress procedure has completed. This robot output signal is used to inform the PLC that the robot is in tip change position. This robot output signal is used to inform the PLC that the robot is clear of the transfer. This robot output signal is used to inform the PLC that the weld controller 1 is executing a weld sequence. 9

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RobotClrZone1

33

RobotClrZone2

34

RobotClrZone3

35

RobotClrZone4

36

RobotClrZone5

37

RobotClrZone6

38

RobotClrZone7

39

RobotClrZone8

40

UserOutput1 UserOutput2 UserOutput3 UserOutput4 UserOutput5 UserOutput6 UserOutput7 UserOutput8 ClrOfPickup1

41 42 43 44 45 46 47 48 49

AtPickup1

50

ClrOfDropoff1

51

AtDropoff1

52

ClrOfPickup2

53

AtPickup2

54

ClrOfDropoff2

55

AtDropoff2

56

ClrOfPickup3

57

AtPickup3

58

ClrOfDropoff3

59

AtDropoff3

60

ClrOfPickup4

61

AtPickup4

62

ClrOfDropoff4

63

AtDropoff4

64

Clr2UnclampEarly

65

RbtAtUserPos1 RbtAtUserPos2

66 67

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This robot output signal is used to inform the PLC that the robot is clear of interference zone 1. This robot output signal is used to inform the PLC that the robot is clear of interference zone 2 This robot output signal is used to inform the PLC that the robot is clear of interference zone 3. This robot output signal is used to inform the PLC that the robot is clear of interference zone 4. This robot output signal is used to inform the PLC that the robot is clear of interference zone 5. This robot output signal is used to inform the PLC that the robot is clear of interference zone 6. This robot output signal is used to inform the PLC that the robot is clear of interference zone 7. This robot output signal is used to inform the PLC that the robot is clear of interference zone 8. This robot output signal is designated as user defined output 1. This robot output signal is designated as user defined output 2. This robot output signal is designated as user defined output 3. This robot output signal is designated as user defined output 4. This robot output signal is designated as user defined output 5. This robot output signal is designated as user defined output 6. This robot output signal is designated as user defined output 7. This robot output signal is designated as user defined output 8. This robot output signal is used to inform the PLC that the robot is clear of pickup 1 position. This robot output signal is used to inform the PLC that the robot is at the pickup 1 position. This robot output signal is used to inform the PLC that the robot is clear of dropoff 1 position. This robot output signal is used to inform the PLC that the robot is at the dropoff 1 position. This robot output signal is used to inform the PLC that the robot is clear of pickup 2 position. This robot output signal is used to inform the PLC that the robot is at the pickup 2 position. This robot output signal is used to inform the PLC that the robot is clear of dropoff 2 position. This robot output signal is used to inform the PLC that the robot is at the dropoff 2 position. This robot output signal is used to inform the PLC that the robot is clear of pickup 3 position. This robot output signal is used to inform the PLC that the robot is at the pickup 3 position. This robot output signal is used to inform the PLC that the robot is clear of dropoff 3 position. This robot output signal is used to inform the PLC that the robot is at the dropoff 3 position. This robot output signal is used to inform the PLC that the robot is clear of pickup 4 position. This robot output signal is used to inform the PLC that the robot is at the pickup 4 position. This robot output signal is used to inform the PLC that the robot is clear of dropoff 4 position. This robot output signal is used to inform the PLC that the robot is at the dropoff 4 position. This robot output signal is used to inform the PLC that the robot is clear to unclamp the tooling. This robot output signal is used to inform the PLC that the robot is at user position 1 This robot output signal is used to inform the PLC that the robot is at user position 2 10

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RbtAtUserPos3 RbtAtUserPos4 Spare Req2EntrToolNest

68 69 70 71

ClearOfToolNest

72

ServiceComp

73

MajorMinorFlt

74

WaitingForPlcCmd

75

RemoveFault RobotPartPres1 RobotPartPres2 RobotPartPres3 RobotPartPres4 RobotPartPres5 RobotPartPres6 RobotPartPres7 RobotPartPres8 RobotPartPres9 RobotPartPres10 LaserEnbld HYagEnbld PickOverride

76 77 78 79 80 81 82 83 84 85 86 87 88 89

CollisGuardEnbld AIr OK AirPressAcptRng WetDryMode AbortPickReq

90 91 92 93 94

TipDressReq Spare ExtPurg1InProgrs

95 96 97

ExtPurg2InProgrs

98

WaterOn WaterOff TurnOnTipDresser StepperResetAck

99 100 101 102

StepMode RobotAtPurgePos RobotClrFixt1

103 104 105

RobotClrFixt2

106

TipBurnInComp Spare ReposTooling1

107 108 109

ReposTooling2 SignatureChgInd

110 111

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This robot output signal is used to inform the PLC that the robot is at user position 3 This robot output signal is used to inform the PLC that the robot is at user position 4 Spare This robot output signal is used as a request from the robot, entry to the tool nests to the PLC. This robot output signal is used to inform the PLC that the robot is clear of the tool nest. This robot output signal is used to signal the PLC that service is complete. This robot output signal is used to signal the PLC that the posted application error is a major fault This robot output signal is used to inform the PLC that the robot is waiting for a PLC command. (Active while in a user program – WaitDI or WaitGI) This robot output signal is used to inform the PLC to remove the application error. This robot output signal is used to inform the PLC that part present 1 is activated. This robot output signal is used to inform the PLC that part present 2 is activated. This robot output signal is used to inform the PLC that part present 3 is activated. This robot output signal is used to inform the PLC that part present 4 is activated. This robot output signal is used to inform the PLC that part present 5 is activated. This robot output signal is used to inform the PLC that part present 6 is activated. This robot output signal is used to inform the PLC that part present 7 is activated. This robot output signal is used to inform the PLC that part present 8 is activated. This robot output signal is used to inform the PLC that part present 9 is activated. This robot output signal is used to inform the PLC that part present 10 is activated. This robot output signal is used to inform the PLC that the Laser is enabled. This robot output signal is used to inform the PLC that the HighYag head is enabled. This robot output signal is used to inform the PLC that the robot is in a pick over ride process. This robot output signal is used to inform the PLC if collision guard is enabled. This robot output indicates the air pressure is OK This robot output indicates the air pressure is within acceptable range. This robot output signal is used to inform the PLC if the robot is in Wet mode. This robot output signal is used to inform the PLC that the robot is requesting the abort pick sequence. This robot output informs the PLC that the weld timer has issued a tip dress request. Spare This robot output signal is used to inform the PLC that dispenser 1 purge sequence is in progress. This robot output signal is used to inform the PLC that dispenser 2 purge sequence is in progress. This robot output signal is used to inform the PLC to turn the water saver on. This robot output signal is used to inform the PLC to turn the water saver off. This robot output signal is used to inform the PLC to turn on the tip dresser motor(s). This robot output signal is used to inform the PLC that the weld controller has reset stepper . This robot output signal is used to inform the PLC that the robot is in StepMode. This robot output indicates the robot is in position to purge. This robot output signal is used to inform the PLC that the robot is clear of fixture 1 (based on automatic zone/window definition in the robot). This robot output signal is used to inform the PLC that the robot is clear of fixture 2 (based on automatic zone/window definition in the robot). This robot output informs the PLC that the tip burn in is complete. Spare This robot output along with the next two bits, (ReposTooling2 – ReposTooling4) grouped as “Group Outputs”, are used to inform the PLC to reposition the tooling. The group outputs are viewed as the binary bit weight viewed as a decimal value. Reference description: “ReposTooling1” This robot output indicates to the PLC that the DCS signature current and previous match and have been verified. 11

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RbtAtInspectPos

112

TeachPendantEnbd

113

StartExtApp1Proc StartExtApp2Proc ToolIDOnWrist1

114 115 116

ToolIDOnWrist2 ToolIDOnWrist4 ProcessFault AppErrorActive

117 118 119 120

AppErrorBit1

121

AppErrorBit2 AppErrorBit4 AppErrorBit8 AppErrorBit16 AppErrorBit32 AppErrorBit64 AppErrorBit128

122 123 124 125 126 127 128

This robot output signal is used to inform the PLC that the robot is at the inspection position. This robot output signal is used to inform the PLC that the teach pendant switch is enabled. This robot output informs the PLC to start external application 1 process. This robot output informs the PLC to start external application 2 process. This robot output signal along with the next two bits, (ToolIDOnWrist2 ToolIDOnWrist4) grouped as “Group Outputs”, are used to inform the PLC which tool is on the robot wrist. The group outputs are viewed as the binary bit weight viewed as a decimal value. Reference description: “ToolIDOnWrist2” Reference description: “ToolIDOnWrist4” This robot output signal is used to inform the PLC that a process fault is present. This robot output signal is used to inform the PLC that an application error is active. Reference: Robot input 8 as acknowledge to this bit. This robot output signal along with the next seven bits, (AppErrorBit2 AppErrorBit128) grouped as “Group Outputs”, are used to inform the PLC of the current value of the application error that is posted. The group outputs are viewed as the binary bit weight viewed as a decimal value. Reference description: “AppErrorBit1” Reference description: “AppErrorBit1” Reference description: “AppErrorBit1” Reference description: “AppErrorBit1” Reference description: “AppErrorBit1” Reference description: “AppErrorBit1” Reference description: “AppErrorBit1”

Reference DCX Book of Implementation Guidelines for proper Tag and UDT Naming – Design standards for Control Logix AMS 0220 Section 9.3.2, 7.0 Tag – DeviceNet Tag Naming Guidelines, Starting on page 28.

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ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT) SIGNAL NAME NoHold

1

ROBOT INPUT #

Resume FaultReset

2 3

20HourRunMode ReqToEnter

4 5

LaserEnable1 LaserGuideOn AppErrorAck

6 7 8

STYLEBit1

9

STYLEBit2 STYLEBit4 STYLEBit8 STYLEBit16 STYLEBit32 STYLEBit64 WeldGunForceChk

10 11 12 13 14 15 16

InterferenceClr1 InterferenceClr2 AcceptVolume

17 18 19

VolumeFltReset

20

PPOK_ClrToGrip GripOK_ClrToExit AbortExitPick AbortExitDrop RetFromPounce

21 22 23 24 25

ServiceCompltReq

26

ServiceRequest

27

TipDressGunReq

28

ProdStart

29

Spare GoToWork

30 31

WorkCompleteAck Zone1ClrToEnter

32 33

Zone2ClrToEnter

34

Zone3ClrToEnter

35

Zone4ClrToEnter

36

AS OF 1/12/2012 Printed copies are not source controlled

DESCRIPTION This robot system input “UI[2:Hold]” is used to decelerate and stop the robot. This signal is held high for normal operation of the robot. This robot system input “UI[6:Start]” is used to resume a paused style program. This robot system input “UI[5:Fault Reset]” is used to reset robot and robot controlled peripheral device faults. This robot input is used to put the robot into 20 hour run mode. This robot input is used to pause the robot program after it has completed the current task and/or motion. This robot input is used to signal the robot to activate the Laser system This robot input is used to signal the robot to activate the Laser Guide This robot input is used as an acknowledgment from the PLC that the application error has been read. This robot system input “UI[9:RSR1/PNS1/STYLE1]” along with the next six bits, grouped as “Group Inputs”, are used for style selection inputs from the PLC. The group inputs are viewed as the binary bit weight in a decimal fashion. System input “UI[10:RSR2/PNS2/STYLE2]” Reference description: “Style1” System input “UI[11:RSR3/PNS3/STYLE3]” Reference description: “Style1” System input “UI[12:RSR4/PNS4/STYLE4]” Reference description: “Style1” System input “UI[13:RSR5/PNS5/STYLE5]” Reference description: “Style1” System input “UI[14:RSR6/PNS6/STYLE6]” Reference description: “Style1” System input “UI[15:RSR7/PNS7/STYLE7]” Reference description: “Style1” This robot input is used to initiate the weld gun force check from a style program at the wait for dropoff position. This robot input is used to signal the robot that interference is clear at area 1. This robot input is used to signal the robot that interference is clear at area 2. This robot input is used to externally accept the sealer bead from the PLC if a volume fault was issued. This robot input is used to externally tell the robot from the PLC to reset a volume fault on the dispense unit. This robot input is used to signal the robot to grip the part. (Used for Clr to Grip part) This robot input is used to signal the robot to exit the position. (Used for Clmp&Hold) This robot input is used to signal the robot to Abort Exit Pick. This robot input is used to signal the robot to Abort Exit Drop. This robot input is used to signal the robot to return from the pounce position back to the home position. When executed, the robot program will return to the home position and mainline program without issuing a “WorkComplete”. This robot input is used to signal the robot to complete the service program and return to home position and mainline program from the service position. This robot input is used to signal the robot to execute a maintenance routine when the robot is at the Waiting for Dropoff# position. (M/H robots only) This robot input is used to signal the robot to initiate the tip dress procedure from a style program. This robot system input “UI[18:Prod Start]” is used to initiate a new style program. When this bit is high and a style number has been set, the robot will start executing the selected style program. [Go to pounce position of selected program] This robot input is not used. This robot input is used to signal the robot to leave “Pounce Position” and execute the work portion of the robot program. This robot input is used to signal that “WorkComplete” was received by the PLC. This robot input is used to inform the robot that interference zone 1 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 2 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 3 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 4 is clear to enter. 13

CUSW REL1.3

Zone5ClrToEnter

37

Zone6ClrToEnter

38

Zone7ClrToEnter

39

Zone8ClrToEnter

40

UserInput1

41

UserInput2

42

UserInput3

43

UserInput4

44

UserInput5

45

UserInput6

46

UserInput7

47

UserInput8

48

GoToPickup1

49

ExitPickup1

50

GoToDropoff1

51

ExitDropoff1

52

GoToPickup2

53

ExitPickup2

54

GoToDropoff2

55

ExitDropoff2

56

GoToPickup3

57

ExitPickup3

58

GoToDropoff3

59

ExitDropoff3

60

GoToPickup4

61

ExitPickup4

62

GoToDropoff4

63

ExitDropoff4

64

Part1InFixture Part2InFixture Part3InFixture

65 66 67

AS OF 1/12/2012 Printed copies are not source controlled

Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 5 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 6 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 7 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 8 is clear to enter. Reference the AME zone logic standard for further information. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is used to signal the robot to continue its program to the pickup 1 position. This robot input is used to signal the robot to continue its program from the pickup 1 position. This robot input is used to signal the robot to continue its program to the dropoff 1 position. This robot input is used to signal the robot to continue its program from the dropoff 1 position. This robot input is used to signal the robot to continue its program to the pickup 2 position. This robot input is used to signal the robot to continue its program from the pickup 2 position. This robot input is used to signal the robot to continue its program to the dropoff 2 position. This robot input is used to signal the robot to continue its program from the dropoff 2 position. This robot input is used to signal the robot to continue its program to the pickup 3 position. This robot input is used to signal the robot to continue its program from the pickup 3 position. This robot input is used to signal the robot to continue its program to the dropoff 3 position. This robot input is used to signal the robot to continue its program from the dropoff 3 position. This robot input is used to signal the robot to continue its program to the pickup 4 position. This robot input is used to signal the robot to continue its program from the pickup 4 position. This robot input is used to signal the robot to continue its program to the dropoff 4 position. This robot input is used to signal the robot to continue its program from the dropoff 4 position. This robot input is used to signal the robot that part 1 is present in the tooling fixture. This robot input is used to signal the robot that part 2 is present in the tooling fixture. This robot input is used to signal the robot that part 3 is present in the tooling fixture. 14

CUSW REL1.3

Part4InFixture Part5InFixture Part6InFixture App1ClrToEnter

68 69 70 71

App2ClrToEnter

72

ToolInNest1 ToolInNest2 ToolInNest3 ToolInNest4 PickTool1

73 74 75 76 77

PickTool2 PickTool4 PickTool8 Clr2EntToolNest ToolingRepod1

78 79 80 81 82

ToolingRepod2 Spare PalletPosBit1

83 84 85

PalletPosBit2 PalletPosBit4 PalletPosBit8 PalletPosBit16 PalletPosBit32 PalletPosBit64 PalletPosBit128 WetDryMode AbortReq PurgeGun1Req

86 87 88 89 90 91 92 93 94 95

PurgeGun2Req

96

WaterFlowOK StartUpPurge

97 98

TipDressDumpExtd TipDrsDumpRetrct TipDrsMotorOn ExtStepperReset1 ExtStepperReset2 TipBurnInReq

99 100 101 102 103 104

TipChgReq

105

InspectRequired InspectComplete ClrToExitUsrPos1 ClrToExitUsrPos2

106 107 108 109

AS OF 1/12/2012 Printed copies are not source controlled

This robot input is used to signal the robot that part 4 is present in the tooling fixture. This robot input is used to signal the robot that part 5 is present in the tooling fixture. This robot input is used to signal the robot that part 6 is present in the tooling fixture. This robot input is used to signal the robot that the process application 1 fixture/area is clear for the robot to enter. This robot input is used to signal the robot that the process application 2 fixture/area is clear for the robot to enter. This robot input is used to inform the robot there is a tool present in nest 1. This robot input is used to inform the robot there is a tool present in nest 2. This robot input is used to inform the robot there is a tool present in nest 3. This robot input is used to inform the robot there is a tool present in nest 4. This robot input along with the next three bits, (PickTool2 – PickTool8) grouped as “Group Inputs”, are used to signal the robot to pick up a specific tool. The group inputs are viewed as the binary bit weight in a decimal fashion. Reference description: “PickTool1” Reference description: “PickTool1” Reference description: “PickTool1” This robot input is used to signal the robot that the tool nest(s) is clear to enter. This robot input along with the next two bits, (ToolingRepod2 – ToolingRepod4) grouped as “Group Inputs”, are used to signal the robot that the tooling/fixture/dumps are repositioned. The group inputs are viewed as the binary bit weight in a decimal fashion. Reference description: “ToolingRepod1” This robot input is not currently used. This robot input along with the next seven bits, (PalletPosBit2 – PalletPosBit128) grouped as “Group Inputs”, are used to signal the robot to move to a specific pallet position. Reference description: “PalletPosBit1” Reference description: “PalletPosBit1” Reference description: “PalletPosBit1” Reference description: “PalletPosBit1” Reference description: “PalletPosBit1” Reference description: “PalletPosBit1” Reference description: “PalletPosBit1” This robot input is used to signal the robot to go into Wet mode. This robot input is used to signal the robot to run an Abort routine. This robot input is used to signal the robot to execute a purge sequence for dispenser 1. This robot input is used to signal the robot to execute a purge sequence for dispenser 2. This robot input is used to signal the robot that water flow is OK. This robot input is used during the sealer purge process to instruct the robot to execute a longer purge time due to the enabling of the sealer unit from conservation mode. This robot input is used to signal the robot that the tip dresser dump is extended. This robot input is used to signal the robot that the tip dresser dump is retracted. This robot input is used to signal the robot that the tip dresser motor is running. This robot input is used to signal the robot to reset weld controller stepper 1. This robot input is used to signal the robot to reset weld controller stepper 2. This robot input is used to call the tip burn in program from the work program while the robot is at home position and from the wait for dropoff position. (Requires input looping) This robot input is used to call the tip change program from the work program while the robot is at home position and from the wait for dropoff position. (Requires input looping) This robot input is used to signal the robot to execute the inspection process. This robot input is used to signal the robot to return from inspection position. This robot input is used to signal the robot that it is clear to exit user position 1. This robot input is used to signal the robot that it is clear to exit user position 2. 15

CUSW REL1.3

ClrToExitUsrPos3 ClrToExitUsrPos4 ClrToExitUsrPos5 ExtApp1StartReq

110 111 112 113

ExtApp1Complete ExtApp2StartReq

114 115

ExtApp2Complete Reseal RejectPart NoSafeSpeed1 ReweldStud

116 117 118 119 120

AcceptStud/Part

121

RejectStud

122

ChangedHead StudSlide1InPos StudSlide2InPos PickOverrideReq

123 124 125 126

TipDressBypass NoSafeSpeed2

127 128

This robot input is used to signal the robot that it is clear to exit user position 3. This robot input is used to signal the robot that it is clear to exit user position 4. This robot input is used to signal the robot that it is clear to exit user position 5. This robot input is used to signal the robot to tell dispense controller 1 to initiate a remote start. This robot input is used to signal the robot that external application 1 is complete. This robot input is used to signal the robot to tell dispense controller 2 to initiate a remote start. This robot input is used to signal the robot that external application 2 is complete. This robot input is used to execute a Reseal process. This robot input is used to execute a Reject Part process This robot input is used to drop the robot into a slow speed during part inspection. This robot input is used to command the robot to issue a Reweld Stud command. (Fault Ack and Start1 or Start2 to ST/W. This robot input is used to command the robot to issue a Accept Stud command. (Fault Ack to ST/W and Weld Complete to robot) Accept Part (MH application) This robot input is used to command the robot to issue a Reject Stud command. (Fault Ack to ST/W and Weld Complete and JumpLbl to Dropoff to the robot. This robot input is used to instruct the robot that the ST/W head has been changed. This robot input indicates to the robot, that studwelder 1 is in the weld position. This robot input indicates to the robot, that studwelder 2 is in the weld position. This robot input indicates to the robot to execute the pick override section of the program This robot input indicates to the robot that the tip dresser is in bypass. This robot input is used to drop the robot into a slow speed during part inspection.

Reference DCX Book of Implementation Guidelines for proper Tag and UDT Naming – Design standards for Control Logix AMS 0220 Section 9.3.2, 7.0 Tag – DeviceNet Tag Naming Guidelines, Starting on page 28.

AS OF 1/12/2012 Printed copies are not source controlled

16

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

SAFETY PLC COMMUNICATIONS

SAFETY PLC COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

NODE ADDRESS

ROBOT ADDRESS

1

CSO 1

ESPB

1

CSI 1

EES

1

CSO 2

RB MTR OFF

1

CSI 2

EGS

1

CSO 3

AUTO

1

CSI 3

SW24V

1

CSO 4

AXP1 MON

1

CSI 4

TC24V

1

CSO 5

TC24V MON

1

CSI 5

spare

1

CSO 6

spare

1

CSI 6

spare

1

CSO 7

DM MON

1

CSI 7

spare

1

CSO 8

CSBP

1

CSI 8

spare

1

CSO 9

spare

1

CSI 9

spare

1

CSO 10

Joint 1 Zone Disabled

1

CSI 10

Joint 1 Zone Disable

1

CSO 11

Joint 2 Zone Disabled

1

CSI 11

Joint 2 Zone Disable

1

CSO 12

spare

1

CSI 12

spare

1

CSO 13

spare

1

CSI 13

spare

1

CSO 14

spare

1

CSI 14

spare

1

CSO 15

spare

1

CSI 15

spare

1

CSO 16

spare

1

CSI 16

spare

SIGNAL NAME

RTU Auto Lube I/O Robot Input # 1 2 3 4 5 6 7 8

RTU Auto Lube I/O

Name PinionCRMon BearingCRMon Pinion24VOkMon Bearing24VOkMon Pinion24VOk Bearing24VOk

AS OF 1/12/2012 Printed copies are not source controlled

SIGNAL NAME

Robot Output # 1 2 3 4 5 6 7 8

17

Name PinionLubeOn BearingLubeOn

CUSW REL1.3

ROBOT IO MAP ASSIGNMENTS OUTPUT ASSIGNMENTS

INPUT ASSIGNMENTS

NODE NUMBER

DO [1 - 128]

DI [1 - 128]

1

SPARES PRECITEC SPOT WELD SCR#1 SPOT WELD SCR#2 SPOT WELD SCR#3 SPOT WELD SCR#4

DO [129 - 192] DO [193 - 352] DO [193 - 224] DO [225 - 256] DO [257 - 288] DO [289 - 320]

DI [129 - 192] DI [193 - 352] DI [193 - 224] DI [225 - 256] DI [257 - 288] DI [289 - 320]

10 11 12 13 14

NELSON STUD WELDER

DO [321 - 384]

DI [321 - 384]

16

DISPENSE #1 DISPENSE #2

DO [385 - 448] DO [449 - 512]

DI [385 - 448] DI [449 - 512]

25 26

DI [513 - 528] DI [529 - 544] DI [545 - 560] DI [561 - 576] DI [577 - 592]

31 32 33 34 35

ROBOT COMMUNICATION PLC COMMUNICATIONS

MH EOAT MODULE #1 INPUT MH EOAT MODULE #2 INPUT MH EOAT MODULE #3 INPUT MH EOAT MODULE #4 INPUT MH EOAT MODULE #5 INPUT MH EOAT MODULE #1 OUTPUT MH EOAT MODULE MISC OUTPUT

DO [513 - 544] DO [545 - 576]

SPARE

DO [577 - 585]

MH EOAT VAC MODULE #1 MH EOAT VAC MODULE #2 USER DEFINABLE IO #1 USER DEFINABLE IO #2

DO [593 - 600] DO [601 - 608] DO [609 - 616] DO [617 - 624]

DI [593 - 600] DI [601 - 608] DI [609 - 616] DI [617 - 624]

SPARE

DO [625 - 631]

DI [625 - 631]

ATI TOOLCHANGER ATI TOOLCHANGER (Robot Internal)

DO [632 - 639] DO [640 - 654]

DI [632 - 695]

54

SPARES

DO [640 - 695]

FORM & PIERCE MOOG FORM & PIERCE CLINCH NUT-FEEDER FORM & PIERCE CLINCH NUT-TOOL FORM & PIERCE PUMP Mig Weld Reamer SPARES TOOLCHANGER COVER / NEST #1 TOOLCHANGER COVER / NEST #2 TOOLCHANGER COVER / NEST #3 TOOLCHANGER COVER / NEST #4

DO [696 - 727] DO [728 - 743] DO [744 - 759] DO [760 - 767] DO (768- 775) DO [776 - 784]

DI [696 - 727] DI [728 - 743] DI [744 - 759] DI [760 - 767] DI (768 - 775) DI [776 - 784]

48 49 50 51 46

IPG_LASERWELD_GENERATOR (ASME) HIGHYAG_HEAD (ASME)

DO [785 - 800] DO [817 - 848]

DI [785 - 800] DI [817 - 848]

17 18

LaserCut Head GrinderMod1 GrinderMod2 GrinderAnalogMod1 GrinderAnalogMod2 Laser Cut Field I/O ISRA OR OTHER VISION

DO [849 - 856] DO [857 - 864] DO [865 - 872] AL 1-1 AL 2-2 AL 1-1 AL 2-2 DO (776- 783) DO [913 - 944]

DO [849 - 856] DO [857 - 864] DO [865 - 872] AL 1-1 AL 2-2 AL 1-1 AL 2-2 DI (776 - 783) DI [913 - 1024]

19 20 21 22 23 24 60

APP ERROR SPARES

DO [945 - 1024]

AS OF 1/12/2012 Printed copies are not source controlled

39 36

37 38 43 44

55 56 57 58

18

CUSW REL1.3

ROBOT BIT MAP ROBOT OUTPUTS PLC COMMUNICATIONS NODE ROBOT ADDRESS ADDRESS 1 DO 1 1 DO 2 1 DO 3 1 DO 4 1 DO 5 1 DO 6 1 DO 7 1 DO 8 1 DO 9 1 DO 10 1 DO 11 1 DO 12 1 DO 13 1 DO 14 1 DO 15 1 DO 16 1 DO 17 1 DO 18 1 DO 19 1 DO 20 1 DO 21 1 DO 22 1 DO 23 1 DO 24 1 DO 25 1 DO 26 1 DO 27 1 DO 28 1 DO 29 1 DO 30 1 DO 31 1 DO 32 1 DO 33 1 DO 34 1 DO 35 1 DO 36 1 DO 37 1 DO 38 1 DO 39 1 DO 40 1 DO 41 1 DO 42 1 DO 43 1 DO 44 1 DO 45 1 DO 46 1 DO 47 1 DO 48 1 DO 49 1 DO 50 1 DO 51 1 DO 52 1 DO 53 1 DO 54 1 DO 55 1 DO 56 1 DO 57 1 DO 58 1 DO 59 1 DO 60 1 DO 61 1 DO 62 1 DO 63 1 DO 64 1 DO 65 1 DO 66 1 DO 67 1 DO 68 1 DO 69 1 DO 70 1 DO 71

PMC ADDRESS Y 0.0 Y 0.1 Y 0.2 Y 0.3 Y 0.4 Y 0.5 Y 0.6 Y 0.7 Y 1.0 Y 1.1 Y 1.2 Y 1.3 Y 1.4 Y 1.5 Y 1.6 Y 1.7 Y 2.0 Y 2.1 Y 2.2 Y 2.3 Y 2.4 Y 2.5 Y 2.6 Y 2.7 Y 3.0 Y 3.1 Y 3.2 Y 3.3 Y 3.4 Y 3.5 Y 3.6 Y 3.7 Y 4.0 Y 4.1 Y 4.2 Y 4.3 Y 4.4 Y 4.5 Y 4.6 Y 4.7 Y 5.0 Y 5.1 Y 5.2 Y 5.3 Y 5.4 Y 5.5 Y 5.6 Y 5.7 Y 6.0 Y 6.1 Y 6.2 Y 6.3 Y 6.4 Y 6.5 Y 6.6 Y 6.7 Y 7.0 Y 7.1 Y 7.2 Y 7.3 Y 7.4 Y 7.5 Y 7.6 Y 7.7 Y 8.0 Y 8.1 Y 8.2 Y 8.3 Y 8.4 Y 8.5 Y 8.6

ROBOT INPUTS PLC COMMUNICATIONS

GROUP ASSIGNMENT

GO[1] GO[1] GO[1] GO[1] GO[1] GO[1] GO[1]

GO[5] GO[5] GO[5] GO[5]

SIGNAL NAME RobotInAuto RobotFaulted WaitForTPInput InCycle CollisionDetd IOSimulated WldEnabled RobotReady ActiveStyBit1 ActiveStyBit2 ActiveStyBit4 ActiveStyBit8 ActiveStyBit16 ActiveStyBit32 ActiveStyBit64 PrgPaused PrgRunning RobotAtWork WorkComplete 20HourRunModeAct MaintReqBit1 MaintReqBit2 MaintReqBit4 MaintReqBit8 RobotAtPounce RobotAtService RobotAtHome RobotInTipDress TipDressComplt RdyForTipChg CleartoTransfer WldInPrgrsActiv1 RbtClrZone1 RbtClrZone2 RbtClrZone3 RbtClrZone4 RbtClrZone5 RbtClrZone6 RbtClrZone7 RbtClrZone8 UserOutput1 UserOutput2 UserOutput3 UserOutput4 UserOutput5 UserOutput6 UserOutput7 UserOutput8 ClrOfPickup1 AtPickup1 ClrOfDropoff1 AtDropoff1 ClrOfPickup2 AtPickup2 ClrOfDropoff2 AtDropoff2 ClrOfPickup3 AtPickup3 ClrOfDropoff3 AtDropoff3 ClrOfPickup4 AtPickup4 ClrOfDropoff4 AtDropoff4 Clr2UnclampEarly RbtAtUserPos1 RbtAtUserPos2 RbtAtUserPos3 RbtAtUserPos4 Spare Req2EntrToolNest

AS OF 1/12/2012 Printed copies are not source controlled

NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 1 DI 1 X 0.0 1 DI 2 X 0.1 1 DI 3 X 0.2 1 DI 4 X 0.3 1 DI 5 X 0.4 1 DI 6 X 0.5 1 DI 7 X 0.6 1 DI 8 X 0.7 1 DI 9 X 1.0 1 DI 10 X 1.1 1 DI 11 X 1.2 1 DI 12 X 1.3 1 DI 13 X 1.4 1 DI 14 X 1.5 1 DI 15 X 1.6 1 DI 16 X 1.7 1 DI 17 X 2.0 1 DI 18 X 2.1 1 DI 19 X 2.2 1 DI 20 X 2.3 1 DI 21 X 2.4 1 DI 22 X 2.5 1 DI 23 X 2.6 1 DI 24 X 2.7 1 DI 25 X 3.0 1 DI 26 X 3.1 1 DI 27 X 3.2 1 DI 28 X 3.3 1 DI 29 X 3.4 1 DI 30 X 3.5 1 DI 31 X 3.6 1 DI 32 X 3.7 1 DI 33 X 4.0 1 DI 34 X 4.1 1 DI 35 X 4.2 1 DI 36 X 4.3 1 DI 37 X 4.4 1 DI 38 X 4.5 1 DI 39 X 4.6 1 DI 40 X 4.7 1 DI 41 X 5.0 1 DI 42 X 5.1 1 DI 43 X 5.2 1 DI 44 X 5.3 1 DI 45 X 5.4 1 DI 46 X 5.5 1 DI 47 X 5.6 1 DI 48 X 5.7 1 DI 49 X 6.0 1 DI 50 X 6.1 1 DI 51 X 6.2 1 DI 52 X 6.3 1 DI 53 X 6.4 1 DI 54 X 6.5 1 DI 55 X 6.6 1 DI 56 X 6.7 1 DI 57 X 7.0 1 DI 58 X 7.1 1 DI 59 X 7.2 1 DI 60 X 7.3 1 DI 61 X 7.4 1 DI 62 X 7.5 1 DI 63 X 7.6 1 DI 64 X 7.7 1 DI 65 X 8.0 1 DI 66 X 8.1 1 DI 67 X 8.2 1 DI 68 X 8.3 1 DI 69 X 8.4 1 DI 70 X 8.5 1 DI 71 X 8.6

19

GROUP ASSIGNMENT

GI[1] GI[1] GI[1] GI[1] GI[1] GI[1] GI[1]

SIGNAL NAME NOHold Resume FaultReset 20HourRunMode ReqToEnter LaserEnable1 LaserGuideOn AppErrorAck STYLEBit1 STYLEBit2 STYLEBit4 STYLEBit8 STYLEBit16 STYLEBit32 STYLEBit64 WeldGunForceChk InterferenceClr1 InterferenceClr2 AcceptVolume VolumeFltReset PPOK_ClrToGrip GripOK_ClrToExit AbortExitPick AbortExitDrop RetFromPounce ServiceCompltReq ServiceRequest TipDressGunReq ProdStart Spare GoToWork WorkCompleteAck Zone1ClrToEnter Zone2ClrToEnter Zone3ClrToEnter Zone4ClrToEnter Zone5ClrToEnter Zone6ClrToEnter Zone7ClrToEnter Zone8ClrToEnter UserInput1 UserInput2 UserInput3 UserInput4 UserInput5 UserInput6 UserInput7 UserInput8 GoToPickup1 ExitPickup1 GoToDropoff1 ExitDropoff1 GoToPickup2 ExitPickup2 GoToDropoff2 ExitDropoff2 GoToPickup3 ExitPickup3 GoToDropoff3 ExitDropoff3 GoToPickup4 ExitPickup4 GoToDropoff4 ExitDropoff4 Part1InFixture Part2InFixture Part3InFixture Part4InFixture Part5InFixture Part6InFixture App1ClrToEnter

CUSW REL1.3

ROBOT OUTPUTS PLC COMMUNICATIONS 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DO 72 DO 73 DO 74 DO 75 DO 76 DO 77 DO 78 DO 79 DO 80 DO 81 DO 82 DO 83 DO 84 DO 85 DO 86 DO 87 DO 88 DO 89 DO 90 DO 91 DO 92 DO 93 DO 94 DO 95 DO 96 DO 97 DO 98 DO 99 DO 100 DO 101 DO 102 DO 103 DO 104 DO 105 DO 106 DO 107 DO 108 DO 109 DO 110 DO 111 DO 112 DO 113 DO 114 DO 115 DO 116 DO 117 DO 118 DO 119 DO 120 DO 121 DO 122 DO 123 DO 124 DO 125 DO 126 DO 127 DO 128

Y 8.7 Y 9.0 Y 9.1 Y 9.2 Y 9.3 Y 9.4 Y 9.5 Y 9.6 Y 9.7 Y 10.0 Y 10.1 Y 10.2 Y 10.3 Y 10.4 Y 10.5 Y 10.6 Y 10.7 Y 11.0 Y 11.1 Y 11.2 Y 11.3 Y 11.4 Y 11.5 Y 11.6 Y 11.7 Y 12.0 Y 12.1 Y 12.2 Y 12.3 Y 12.4 Y 12.5 Y 12.6 Y 12.7 Y 13.0 Y 13.1 Y 13.2 Y 13.3 Y 13.4 Y 13.5 Y 13.6 Y 13.7 Y 14.0 Y 14.1 Y 14.2 Y 14.3 Y 14.4 Y 14.5 Y 14.6 Y 14.7 Y 15.0 Y 15.1 Y 15.2 Y 15.3 Y 15.4 Y 15.5 Y 15.6 Y 15.7

ROBOT INPUTS PLC COMMUNICATIONS

GO[2] GO[2]

GO[3] GO[3] GO[3]

GO[4] GO[4] GO[4] GO[4] GO[4] GO[4] GO[4] GO[4]

ClearOfToolNest ServiceComp MajorMinorFlt WaitingForPlcCmd RemoveFault RobotPartPres1 RobotPartPres2 RobotPartPres3 RobotPartPres4 RobotPartPres5 RobotPartPres6 RobotPartPres7 RobotPartPres8 RobotPartPres9 RobotPartPres10 LaserEnbld HYagEnbld PickOverride CollisGuardEnbld AirOK AirPressAcptRng WetDryMode AbortPickReq TipDressReq Spare ExtPurg1InProgrs ExtPurg2InProgrs WaterOn WaterOff TurnOnTipDresser StepperRstAck StepMode RobotAtPurgePos RobotClrFixt1 RobotClrFixt2 TipBurnInComp Spare ReposTooling1 ReposTooling2 SignatureChgInd RbtAtInspectPos TeachPendantEnbd StartExtApp1Proc StartExtApp1Proc ToolIDOnWrist1 ToolIDOnWrist2 ToolIDOnWrist4 ProcessFault AppErrorActive AppErorrBit1 AppErrorBit2 AppErrorBit4 AppErrorBit8 AppErrorBit16 AppErrorBit32 AppErrorBit64 AppErrorBit128

AS OF 1/12/2012 Printed copies are not source controlled

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

20

DI 72 DI 73 DI 74 DI 75 DI 76 DI 77 DI 78 DI 79 DI 80 DI 81 DI 82 DI 83 DI 84 DI 85 DI 86 DI 87 DI 88 DI 89 DI 90 DI 91 DI 92 DI 93 DI 94 DI 95 DI 96 DI 97 DI 98 DI 99 DI 100 DI 101 DI 102 DI 103 DI 104 DI 105 DI 106 DI 107 DI 108 DI 109 DI 110 DI 111 DI 112 DI 113 DI 114 DI 115 DI 116 DI 117 DI 118 DI 119 DI 120 DI 121 DI 122 DI 123 DI 124 DI 125 DI 126 DI 127 DI 128

X 8.7 X 9.0 X 9.1 X 9.2 X 9.3 X 9.4 X 9.5 X 9.6 X 9.7 X 10.0 X 10.1 X 10.2 X 10.3 X 10.4 X 10.5 X 10.6 X 10.7 X 11.0 X 11.1 X 11.2 X 11.3 X 11.4 X 11.5 X 11.6 X 11.7 X 12.0 X 12.1 X 12.2 X 12.3 X 12.4 X 12.5 X 12.6 X 12.7 X 13.0 X 13.1 X 13.2 X 13.3 X 13.4 X 13.5 X 13.6 X 13.7 X 14.0 X 14.1 X 14.2 X 14.3 X 14.4 X 14.5 X 14.6 X 14.7 X 15.0 X 15.1 X 15.2 X 15.3 X 15.4 X 15.5 X 15.6 X 15.7

GI[4] GI[4] GI[4] GI[4] GI[5] GI[5] GI[6] GI[6] GI[6] GI[6] GI[6] GI[6] GI[6] GI[6]

App2ClrToEnter ToolInNest1 ToolInNest2 ToolInNest3 ToolInNest4 PickTool1 PickTool2 PickTool4 PickTool8 Clr2EntToolNest ToolingRepod1 ToolingRepod2 Spare PalletPosBit1 PalletPosBit2 PalletPosBit4 PalletPosBit8 PalletPosBit16 PalletPosBit32 PalletPosBit64 PalletPosBit128 WetDryMode AbortReq PurgeGun1Req PurgeGun2Req WaterFlowOK StartUpPurge TipDressDumpExtd TipDrsDumpRetrct TipDrsMotorOn ExtStepperReset1 ExtStepperReset2 TipBurnInReq TipChgReq InspectRequired InspectComplete ClrToExitUsrPos1 ClrToExitUsrPos2 ClrToExitUsrPos3 ClrToExitUsrPos4 ClrToExitUsrPos5 ExtApp1StartReq ExtApp1Complete ExtApp2StartReq ExtApp2Complete Reseal RejectPart NoSafeSpeed1 ReweldStud AcceptStud/Part RejectStud ChangedHead StudSlide1InPos StudSlide2InPos PickOverrideReq TipDressBypass NoSafeSpeed2

CUSW REL1.3

ROBOT OUTPUTS PLC COMMUNICATIONS Precitec NODE ADDRESS 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

ROBOT ADDRESS DO 129 DO 130 DO 131 DO 132 DO 133 DO 134 DO 135 DO 136 DO 137 DO 138 DO 139 DO 140 DO 141 DO 142 DO 143 DO 144 DO 145 DO 146 DO 147 DO 148 DO 149 DO 150 DO 151 DO 152 DO 153 DO 154 DO 155 DO 156 DO 157 DO 158 DO 159 DO 160 DO 161 DO 162 DO 163 DO 164 DO 165 DO 166 DO 167 DO 168 DO 169 DO 170 DO 171 DO 172 DO 173 DO 174 DO 175 DO 176 DO 177 DO 178 DO 179 DO 180 DO 181 DO 182 DO 183 DO 184 DO 185 DO 186 DO 187 DO 188 DO 189 DO 190 DO 191 DO 192

PMC ADDRESS

GROUP ASSIGNMENT

ROBOT INPUTS PLC COMMUNICATIONS Precitec

SIGNAL NAME Part OK Part Not OK Inspection Incomplete Line Stop Not OK Left Side Not OK Right Side Reserved Reserved Seam Fault Generic Term A Seam Fault Generic Term B Seam Fault Generic Term C Reserved Reserved Reserved Reserved Reserved System Ready Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

AS OF 1/12/2012 Printed copies are not source controlled

NODE ADDRESS 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

21

ROBOT PMC ADDRESS ADDRESS DI 129 DI 130 DI 131 DI 132 DI 133 DI 134 DI 135 DI 136 DI 137 DI 138 DI 139 DI 140 DI 141 DI 142 DI 143 DI 144 DI 145 DI 146 DI 147 DI 148 DI 149 DI 150 DI 151 DI 152 DI 153 DI 154 DI 155 DI 156 DI 157 DI 158 DI 159 DI 160 DI 161 DI 162 DI 163 DI 164 DI 165 DI 166 DI 167 DI 168 DI 169 DI 170 DI 171 DI 172 DI 173 DI 174 DI 175 DI 176 DI 177 DI 178 DI 179 DI 180 DI 181 DI 182 DI 183 DI 184 DI 185 DI 186 DI 187 DI 188 DI 189 DI 190 DI 191 DI 192

GROUP ASSIGNMENT

SIGNAL NAME Part No Bit 0 Part No Bit 1 Part No Bit 2 Part No Bit 3 Part No Bit 4 Part No Bit 5 Part No Bit 6 Part No Bit 7 Part No Bit 8 Part No Bit 9 Part No Bit 10 Part No Bit 11 Part No Bit 12 Part No Bit 13 Part No Bit 14 Part No Bit 15 Part No Bit 16 Part No Bit 16 Part No Bit 18 Part No Bit 19 Part No Bit 20 Part No Bit 21 Part No Bit 22 Part No Bit 23 Part No Bit 24 Part No Bit 25 Part No Bit 26 Part No Bit 27 Part No Bit 28 Part No Bit 29 Part No Bit 30 Part No Bit 31 Part Type Bit 0 Part Type Bit 1 Part Type Bit 2 Part Type Bit 3 Part Type Bit 4 Part Type Bit 5 Part Type Bit 6 Part Type Bit 7 Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

PRECITEC COMMUNICATIONS NODE ADDRESS 10 10 10 10 10 10 10 10

ROBOT ADDRESS DO 193 DO 194 DO 195 DO 196 DO 197 DO 198 DO 199 DO 200

10

DO 201

10

DO 202

10 10

DO 203 DO 204

10

DO 205

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

DO 206 DO 207 DO 208 DO 209 DO 210 DO 211 DO 212 DO 213 DO 214 DO 215 DO 216 DO 217 DO 218 DO 219 DO 220 DO 221 DO 222 DO 223 DO 224 DO 225 DO 226 DO 227 DO 228 DO 229 DO 230 DO 231 DO 232 DO 233 DO 234 DO 235 DO 236 DO 237 DO 238 DO 239 DO 240 DO 241 DO 242 DO 243 DO 244 DO 245 DO 246 DO 247 DO 248 DO 249 DO 250 DO 251 DO 252 DO 253 DO 254 DO 255 DO 256 DO 257 DO 258 DO 259 DO 260 DO 261 DO 262 DO 263

PMC ADDRESS Y 0.0

PRECITEC COMMUNICATIONS GROUP ASSIGNMENT

AS OF 1/12/2012 Printed copies are not source controlled

SIGNAL NAME Seam Sequence number Bit 0 Seam Sequence number Bit 1 Seam Sequence number Bit 2 Seam Sequence number Bit 3 Seam Sequence number Bit 4 Seam Sequence number Bit 5 Seam Sequence number Bit 6 Seam Sequence number Bit 7 Seam number Bit 0

NODE ADDRESS 10 10 10 10 10 10 10 10 10

Seam number Bit 1

10

Seam number Bit 2 Seam number Bit 3 Seam number Bit 4

10 10

Seam number Bit 5 Seam number Bit 6 Seam number Bit 7

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

10

Inspection part active Take-over Seam Seq. No Inspection seam active Linelaser on No images Air nozzle on Select inkjet reserved Error code left Error code right reserved reserved reserved reserved reserved reserved Quit system fault reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved Calibration active reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

22

ROBOT PMC GROUP ADDRESSADDRESS ASSIGNMENT SIGNAL NAME DI 193 X 0.0 System fault: no laserlines DI 194 System fault: no flasht DI 195 System fault: camera problem DI 196 System fault: reserved DI 197 System fault: internal software problem DI 198 System fault: autofocus-axis DI 199 System fault: reserved DI 200 System fault: reserved System fault: wrong position of sensor DI 201 head System fault: seam start/seam end not DI 202 detected DI 203 System fault: reserved DI 204 System fault: reserved System fault: Air conditioner / cabinet DI 205 temperature DI 206 System fault: inkjet has fault DI 207 System fault: inkjet has warning DI 208 System fault: reserved DI 209 Part OK (OK=1) DI 210 Part NOK (NOK = 1) DI 211 Inspection incomplete DI 212 Linestop (Stop = 1) DI 213 NOK left side DI 214 NOK right side DI 215 reserved DI 216 reserved DI 217 Seam fault generic term A DI 218 Seam fault generic term B DI 219 Seam fault generic term C DI 220 reserved DI 221 reserved DI 222 reserved DI 223 reserved DI 224 reserved DI 225 System ready (collective signal) DI 226 Sensor ready DI 227 Inkjet ready DI 228 reserved DI 229 reserved DI 230 reserved DI 231 reserved DI 232 reserved DI 233 reserved DI 234 reserved DI 235 reserved DI 236 reserved DI 237 reserved DI 238 reserved DI 239 reserved DI 240 reserved DI 241 Calibration request DI 242 Calibration finished DI 243 Calibration OK DI 244 Calibration NOK DI 245 reserved DI 246 reserved DI 247 reserved DI 248 reserved DI 249 reserved DI 250 reserved DI 251 reserved DI 252 reserved DI 253 reserved DI 254 reserved DI 255 reserved DI 256 reserved DI 257 reserved DI 258 reserved DI 259 reserved DI 260 reserved DI 261 reserved DI 262 reserved DI 263 reserved

CUSW REL1.3

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

DO 264 DO 265 DO 266 DO 267 DO 268 DO 269 DO 270 DO 271 DO 272 DO 273 DO 274 DO 275 DO 276 DO 277 DO 278 DO 279 DO 280 DO 281 DO 282 DO 283 DO 284 DO 285 DO 286 DO 287 DO 288 DO 289 DO 290 DO 291 DO 292 DO 293 DO 294 DO 295 DO 296 DO 297 DO 298

10

DO 299

10

DO 300

10

DO 301

10

DO 302

10

DO 303

10

DO 304

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

DO 305 DO 306 DO 307 DO 308 DO 309 DO 310 DO 311 DO 312 DO 313 DO 314 DO 315 DO 316 DO 317 DO 318 DO 319 DO 320 DO 321 DO 322 DO 323 DO 324 DO 325 DO 326 DO 327 DO 328 DO 329 DO 330 DO 331 DO 332 DO 333 DO 334 DO 335 DO 336 DO 337 DO 338 DO 339

AS OF 1/12/2012 Printed copies are not source controlled

reserved reserved reserved reserved reserved reserved reserved reserved reserved Part-No Bit 0 (Year Bit 0) Part-No Bit 1 (Year Bit 1) Part-No Bit 2 (Year Bit 2) Part-No Bit 3 (Year Bit 3) Part-No Bit 4 (Day Bit 0) Part-No Bit 5 (Day Bit 1) Part-No Bit 6 (Day Bit 2) Part-No Bit 7 (Day Bit 3) Part-No Bit 8 (Day Bit 4) Part-No Bit 9 (Day Bit 5) Part-No Bit 10 (Day Bit 6) Part-No Bit 11 (Day Bit 7) Part-No Bit 12 (Day Bit 8) Part-No Bit 13 (Day Bit 9) Part-No Bit 14 (Day Bit 10) Part-No Bit 15 (Day Bit 11) Part-No Bit 16 (Current no Bit 0) Part-No Bit 17 (Current no Bit 1) Part-No Bit 18 (Current no Bit 2) Part-No Bit 19 (Current no Bit 3) Part-No Bit 20 (Current no Bit 4) Part-No Bit 21 (Current no Bit 5) Part-No Bit 22 (Current no Bit 6) Part-No Bit 23 (Current no Bit 7) Part-No Bit 24 (Current no Bit 8) Part-No Bit 25 (Current no Bit 9) Part-No Bit 26 (Current no Bit 10) Part-No Bit 27 (Current no Bit 11) Part-No Bit 28 (Current no Bit 12) Part-No Bit 29 (Current no Bit 13) Part-No Bit 30 (Current no Bit 14) Part-No Bit 31 (Current no Bit 15) Part-No Bit 32 Part-No Bit 33 Part-No Bit 34 Part-No Bit 35 Part-No Bit 36 Part-No Bit 37 Part-No Bit 38 Part-No Bit 39 Part-No Bit 40 Part-No Bit 41 Part-No Bit 42 Part-No Bit 43 Part-No Bit 44 Part-No Bit 45 Part-No Bit 46 Part-No Bit 47 Part-Type Bit 0 Part-Type Bit 1 Part-Type Bit 2 Part-Type Bit 3 Part-Type Bit 4 Part-Type Bit 5 Part-Type Bit 6 Part-Type Bit 7 reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

23

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

DI 264 DI 265 DI 266 DI 267 DI 268 DI 269 DI 270 DI 271 DI 272 DI 273 DI 274 DI 275 DI 276 DI 277 DI 278 DI 279 DI 280 DI 281 DI 282 DI 283 DI 284 DI 285 DI 286 DI 287 DI 288 DI 289 DI 290 DI 291 DI 292 DI 293 DI 294 DI 295 DI 296 DI 297 DI 298

reserved reserved reserved reserved reserved reserved reserved reserved reserved Part-No Bit 0 (Year Bit 0) Part-No Bit 1 (Year Bit 1) Part-No Bit 2 (Year Bit 2) Part-No Bit 3 (Year Bit 3) Part-No Bit 4 (Day Bit 0) Part-No Bit 5 (Day Bit 1) Part-No Bit 6 (Day Bit 2) Part-No Bit 7 (Day Bit 3) Part-No Bit 8 (Day Bit 4) Part-No Bit 9 (Day Bit 5) Part-No Bit 10 (Day Bit 6) Part-No Bit 11 (Day Bit 7) Part-No Bit 12 (Day Bit 8) Part-No Bit 13 (Day Bit 9) Part-No Bit 14 (Day Bit 10) Part-No Bit 15 (Day Bit 11)

10

DI 299

Part-No Bit 26 (Current no Bit 10)

10

DI 300

Part-No Bit 27 (Current no Bit 11)

10

DI 301

Part-No Bit 28 (Current no Bit 12)

10

DI 302

Part-No Bit 29 (Current no Bit 13)

10

DI 303

Part-No Bit 30 (Current no Bit 14)

10

DI 304

Part-No Bit 31 (Current no Bit 15)

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

DI 305 DI 306 DI 307 DI 308 DI 309 DI 310 DI 311 DI 312 DI 313 DI 314 DI 315 DI 316 DI 317 DI 318 DI 319 DI 320

Part-No Bit 32 Part-No Bit 33 Part-No Bit 34 Part-No Bit 35 Part-No Bit 36 Part-No Bit 37 Part-No Bit 38 Part-No Bit 39 Part-No Bit 40 Part-No Bit 41 Part-No Bit 42 Part-No Bit 43 Part-No Bit 44 Part-No Bit 45 Part-No Bit 46 Part-No Bit 47 Part-Type Bit 0 Part-Type Bit 1 Part-Type Bit 2 Part-Type Bit 3 Part-Type Bit 4 Part-Type Bit 5 Part-Type Bit 6 Part-Type Bit 7 reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

Part-No Bit 16 (Current no Bit 0) Part-No Bit 17 (Current no Bit 1) Part-No Bit 18 (Current no Bit 2) Part-No Bit 19 (Current no Bit 3) Part-No Bit 20 (Current no Bit 4) Part-No Bit 21 (Current no Bit 5) Part-No Bit 22 (Current no Bit 6) Part-No Bit 23 (Current no Bit 7) Part-No Bit 24 (Current no Bit 8) Part-No Bit 25 (Current no Bit 9)

CUSW REL1.3

10 10 10 10 10 10 10 10 10 10 10 10 10

DO 340 DO 341 DO 342 DO 343 DO 344 DO 345 DO 346 DO 347 DO 348 DO 349 DO 350 DO 351 DO 352

reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

10 10 10 10 10 10 10 10 10 10 10 10 10

reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

Note: Configuration of the Precitec must done manually by the robot programmer. The robot must be set up with the custo as a material handling robot and spotwelding and studwelding cannot be configured.

AS OF 1/12/2012 Printed copies are not source controlled

24

CUSW REL1.3

ROBOT OUTPUTS SPOT WELD SCR#1 COMMUNICATIONS NODE ADDRESS 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11 11

ROBOT ADDRESS DO 193 DO 194 DO 195 DO 196 DO 197 DO 198 DO 199 DO 200 DO 201 DO 202 DO 203 DO 204 DO 205 DO 206 DO 207 DO 208 DO 209 DO 210 DO 211 DO 212 DO 213 DO 214 DO 215 DO 216 DO 217 DO 218 DO 219 DO 220 DO 221 DO 222 DO 223 DO 224

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

GO[11] GO[11] GO[11] GO[11] GO[11] GO[11]

GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12]

ROBOT INPUTS SPOT WELD SCR#1 COMMUNICATIONS

SIGNAL NAME W1EnableWld W1FaultRst W1WldFltAck W1PrgBit1 W1PrgBit2 W1PrgBit4 W1PrgBit8 W1PrgBit16 W1PrgBit32 W1InitiateWld W1PressTest W1InitRet W1RstStepper W1IsoContSvrEnb W1ControlStop W1Tipsdressed W1WldIDBit1 W1WldIDBit2 W1WldIDBit4 W1WldIDBit8 W1WldIDBit16 W1WldIDBit32 W1WldIDBit64 W1WldIDBit128 W1WldIDBit256 W1WldIDBit512 W1WldIDBit1024 W1WldIDBit2048 W1WldIDBit4096 W1WldIDBit8192 Spare Spare

NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 11 DI 193 X 0.0 11 DI 194 11 DI 195 11 DI 196 11 DI 197 11 DI 198 11 DI 199 11 DI 200 11 DI 201 11 DI 202 11 DI 203 11 DI 204 11 DI 205 11 DI 206 11 DI 207 11 DI 208 11 DI 209 11 DI 210 11 DI 211 11 DI 212 11 DI 213 11 DI 214 11 DI 215 11 DI 216 11 DI 217 11 DI 218 11 DI 219 11 DI 220 11 DI 221 11 DI 222 11 DI 223 11 DI 224

ROBOT OUTPUTS SPOT WELD SCR#2 COMMUNICATIONS NODE ADDRESS 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12

ROBOT ADDRESS DO 225 DO 226 DO 227 DO 228 DO 229 DO 230 DO 231 DO 232 DO 233 DO 234 DO 235 DO 236 DO 237 DO 238 DO 239 DO 240 DO 241 DO 242 DO 243 DO 244 DO 245 DO 246 DO 247 DO 248 DO 249 DO 250 DO 251 DO 252 DO 253 DO 254 DO 255 DO 256

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

GO[13] GO[13] GO[13] GO[13] GO[13] GO[13]

GO[14] GO[14] GO[14] GO[14] GO[14] GO[14] GO[14] GO[14] GO[14] GO[14] GO[14] GO[14] GO[14] GO[14]

GROUP ASSIGNMENT

GI[11] GI[11] GI[11] GI[11] GI[11]

SIGNAL NAME W1WeldEnabled W1NoFault W1NoAlert W1WeldFltAvail W1WeldFltBit1 W1WeldFltBit2 W1WeldFltBit4 W1WeldFltBit8 W1WeldFltBit16 W1WeldComplete W1WeldInProgres W1SteppersReset W1NearEndOfStep W1EndOfStepper W1ReadyToWeld W1DressTipsReq W1RetractOut#1 W1RetractOut#2 W1FltMSGCode W1AlrtMSGCode Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

ROBOT INPUTS SPOT WELD SCR#2 COMMUNICATIONS

SIGNAL NAME W2EnableWld W2FaultRst W2WldFltAck W2PrgBit1 W2PrgBit2 W2PrgBit4 W2PrgBit8 W2PrgBit16 W2PrgBit32 W2InitiateWld W2PressTest W2InitRet W2RstStepper W2IsoContSvrEnb W2ControlStop W2Tipsdressed W2WldIDBit1 W2WldIDBit2 W2WldIDBit4 W2WldIDBit8 W2WldIDBit16 W2WldIDBit32 W2WldIDBit64 W2WldIDBit128 W2WldIDBit256 W2WldIDBit512 W2WldIDBit1024 W2WldIDBit2048 W2WldIDBit4096 W2WldIDBit8192 Spare Spare

AS OF 1/12/2012 Printed copies are not source controlled

NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 12 DI 225 X 0.0 12 DI 226 12 DI 227 12 DI 228 12 DI 229 12 DI 230 12 DI 231 12 DI 232 12 DI 233 12 DI 234 12 DI 235 12 DI 236 12 DI 237 12 DI 238 12 DI 239 12 DI 240 12 DI 241 12 DI 242 12 DI 243 12 DI 244 12 DI 245 12 DI 246 12 DI 247 12 DI 248 12 DI 249 12 DI 250 12 DI 251 12 DI 252 12 DI 253 12 DI 254 12 DI 255 12 DI 256

25

GROUP ASSIGNMENT

GI[13] GI[13] GI[13] GI[13] GI[13]

SIGNAL NAME W2WeldEnabled W2NoFault W2NoAlert W2WeldFltAvail W2WeldFltBit1 W2WeldFltBit2 W2WeldFltBit4 W2WeldFltBit8 W2WeldFltBit16 W2WeldComplete W2WeldInProgres W2SteppersReset W2NearEndOfStep W2EndOfStepper W2ReadyToWeld W2DressTipsReq W2RetractOut#1 W2RetractOut#2 W2FltMSGCode W2AlrtMSGCode Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

CUSW REL1.3

ROBOT OUTPUTS SPOT WELD SCR#3 COMMUNICATIONS NODE ADDRESS 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13

ROBOT ADDRESS DO 257 DO 258 DO 259 DO 260 DO 261 DO 262 DO 263 DO 264 DO 265 DO 266 DO 267 DO 268 DO 269 DO 270 DO 271 DO 272 DO 273 DO 274 DO 275 DO 276 DO 277 DO 278 DO 279 DO 280 DO 281 DO 282 DO 283 DO 284 DO 285 DO 286 DO 287 DO 288

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

GO[15] GO[15] GO[15] GO[15] GO[15] GO[15]

GO[16] GO[16] GO[16] GO[16] GO[16] GO[16] GO[16] GO[16] GO[16] GO[16] GO[16] GO[16] GO[16] GO[16]

ROBOT INPUTS SPOT WELD SCR#3 COMMUNICATIONS

SIGNAL NAME W3EnableWld W3FaultRst W3WldFltAck W3PrgBit1 W3PrgBit2 W3PrgBit4 W3PrgBit8 W3PrgBit16 W3PrgBit32 W3InitiateWld W3PressTest W3InitRet W3RstStepper W3IsoContSvrEnb W3ControlStop W3Tipsdressed W3WldIDBit1 W3WldIDBit2 W3WldIDBit4 W3WldIDBit8 W3WldIDBit16 W3WldIDBit32 W3WldIDBit64 W3WldIDBit128 W3WldIDBit256 W3WldIDBit512 W3WldIDBit1024 W3WldIDBit2048 W3WldIDBit4096 W3WldIDBit8192 Spare Spare

NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 13 DI 257 X 0.0 13 DI 258 13 DI 259 13 DI 260 13 DI 261 13 DI 262 13 DI 263 13 DI 264 13 DI 265 13 DI 266 13 DI 267 13 DI 268 13 DI 269 13 DI 270 13 DI 271 13 DI 272 13 DI 273 13 DI 274 13 DI 275 13 DI 276 13 DI 277 13 DI 278 13 DI 279 13 DI 280 13 DI 281 13 DI 282 13 DI 283 13 DI 284 13 DI 285 13 DI 286 13 DI 287 13 DI 288

ROBOT OUTPUTS SPOT WELD SCR#4 COMMUNICATIONS NODE ADDRESS 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14

ROBOT ADDRESS DO 289 DO 290 DO 291 DO 292 DO 293 DO 294 DO 295 DO 296 DO 297 DO 298 DO 299 DO 300 DO 301 DO 302 DO 303 DO 304 DO 305 DO 306 DO 307 DO 308 DO 309 DO 310 DO 311 DO 312 DO 313 DO 314 DO 315 DO 316 DO 317 DO 318 DO 319 DO 320

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

GO[17] GO[17] GO[17] GO[17] GO[17] GO[17]

GO[18] GO[18] GO[18] GO[18] GO[18] GO[18] GO[18] GO[18] GO[18] GO[18] GO[18] GO[18] GO[18] GO[18]

GROUP ASSIGNMENT

GI[15] GI[15] GI[15] GI[15] GI[15]

SIGNAL NAME W3WeldEnabled W3NoFault W3NoAlert W3WeldFltAvail W3WeldFltBit1 W3WeldFltBit2 W3WeldFltBit4 W3WeldFltBit8 W3WeldFltBit16 W3WeldComplete W3WeldInProgres W3SteppersReset W3NearEndOfStep W3EndOfStepper W3ReadyToWeld W3DressTipsReq W3RetractOut#1 W3RetractOut#2 W3FltMSGCode W3AlrtMSGCode Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

ROBOT INPUTS SPOT WELD SCR#4 COMMUNICATIONS

SIGNAL NAME W4EnableWld W4FaultRst W4WldFltAck W4PrgBit1 W4PrgBit2 W4PrgBit4 W4PrgBit8 W4PrgBit16 W4PrgBit32 W4InitiateWld W4PressTest W4InitRet W4RstStepper W4IsoContSvrEnb W4ControlStop W4Tipsdressed W4WldIDBit1 W4WldIDBit2 W4WldIDBit4 W4WldIDBit8 W4WldIDBit16 W4WldIDBit32 W4WldIDBit64 W4WldIDBit128 W4WldIDBit256 W4WldIDBit512 W4WldIDBit1024 W4WldIDBit2048 W4WldIDBit4096 W4WldIDBit8192 Spare Spare

AS OF 1/12/2012 Printed copies are not source controlled

NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 14 DI 289 X 0.0 14 DI 290 14 DI 291 14 DI 292 14 DI 293 14 DI 294 14 DI 295 14 DI 296 14 DI 297 14 DI 298 14 DI 299 14 DI 300 14 DI 301 14 DI 302 14 DI 303 14 DI 304 14 DI 305 14 DI 306 14 DI 307 14 DI 308 14 DI 309 14 DI 310 14 DI 311 14 DI 312 14 DI 313 14 DI 314 14 DI 315 14 DI 316 14 DI 317 14 DI 318 14 DI 319 14 DI 320

26

GROUP ASSIGNMENT

GI[17] GI[17] GI[17] GI[17] GI[17]

SIGNAL NAME W4WeldEnabled W4NoFault W4NoAlert W4WeldFltAvail W4WeldFltBit1 W4WeldFltBit2 W4WeldFltBit4 W4WeldFltBit8 W4WeldFltBit16 W4WeldComplete W4WeldInProgres W4SteppersReset W4NearEndOfStep W4EndOfStepper W4ReadyToWeld W4DressTipsReq W4RetractOut#1 W4RetractOut#2 W4FltMSGCode W4AlrtMSGCode Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

CUSW REL1.3

ROBOT OUTPUTS NELSON STUD WELDER COMMUNICATIONS NODE ADDRESS 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16

ROBOT ADDRESS DO 321 DO 322 DO 323 DO 324 DO 325 DO 326 DO 327 DO 328 DO 329 DO 330 DO 331 DO 332 DO 333 DO 334 DO 335 DO 336 DO 337 DO 338 DO 339 DO 340 DO 341 DO 342 DO 343 DO 344 DO 345 DO 346 DO 347 DO 348 DO 349 DO 350 DO 351 DO 352 DO 353 DO 354 DO 355 DO 356 DO 357 DO 358 DO 359 DO 360 DO 361 DO 362 DO 363 DO 364 DO 365 DO 366 DO 367 DO 368 DO 369 DO 370 DO 371 DO 372 DO 373 DO 374 DO 375 DO 376 DO 377 DO 378 DO 379 DO 380 DO 381 DO 382 DO 383 DO 384

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

GO[21] GO[21] GO[21] GO[21] GO[21] GO[21] GO[21] GO[21]

GO[22] GO[22]

SIGNAL NAME StartWeld1 StartWeld2 StartWeld3 StartWeld4 StartWeld5 FeedStud1 FeedStud2 FeedStud3 FeedStud4 FeedStud5 SelectProgBit1 SelectProgBit2 SelectProgBit4 SelectProgBit8 SelectProgBit16 SelectProgBit32 SelectProgBit64 SelectProgBit128 Restart SetWeldComp SelectOperMode0 SelectOperMode1 ResetFault Std1Output24 Std1Output25 Std1Output26 Std1Output27 Std1Output28 Std1Output29 Std1Output30 Std1Output31 Std1Output32 Std1Output33 Std1Output34 Std1Output35 Std1Output36 Std1Output37 Std1Output38 Std1Output39 Std1Output40 Std1Output41 Std1Output42 Std1Output43 Std1Output44 Std1Output45 Std1Output46 Std1Output47 Std1Output48 AdvWeldGun1 AdvWeldGun2 AdvWeldGun3 AdvWeldGun4 AdvWeldGun5 Std1Output54 Std1Output55 Std1Output56 Std1Output57 Std1Output58 Std1Output59 Std1Output60 Std1Output61 Std1Output62 Std1Output63 Std1Output64

AS OF 1/12/2012 Printed copies are not source controlled

ROBOT INPUTS NELSON STUD WELDER COMMUNICATIONS NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 16 DI 321 X 0.0 16 DI 322 16 DI 323 16 DI 324 16 DI 325 16 DI 326 16 DI 327 16 DI 328 16 DI 329 16 DI 330 16 DI 331 16 DI 332 16 DI 333 16 DI 334 16 DI 335 16 DI 336 16 DI 337 16 DI 338 16 DI 339 16 DI 340 16 DI 341 16 DI 342 16 DI 343 16 DI 344 16 DI 345 16 DI 346 16 DI 347 16 DI 348 16 DI 349 16 DI 350 16 DI 351 16 DI 352 16 DI 353 16 DI 354 16 DI 355 16 DI 356 16 DI 357 16 DI 358 16 DI 359 16 DI 360 16 DI 361 16 DI 362 16 DI 363 16 DI 364 16 DI 365 16 DI 366 16 DI 367 16 DI 368 16 DI 369 16 DI 370 16 DI 371 16 DI 372 16 DI 373 16 DI 374 16 DI 375 16 DI 376 16 DI 377 16 DI 378 16 DI 379 16 DI 380 16 DI 381 16 DI 382 16 DI 383 16 DI 384

27

GROUP ASSIGNMENT

GI[22] GI[22] GI[22] GI[22] GI[22] GI[22] GI[22] GI[22]

SIGNAL NAME NOError1 WeldComp1 WeldGunRetrctd1 StudTouchingWrk1 SuspectWeld1 NOError2 WeldComp2 WeldGunRetrctd2 StudTouchingWrk2 SuspectWeld2 NOError3 WeldComp3 WeldGunRetrctd3 StudTouchingWrk3 SuspectWeld3 NOError4 WeldComp4 WeldGunRetrctd4 StudTouchingWrk4 SuspectWeld4 NOError5 WeldComp5 WeldGunRetrctd5 StudTouchingWrk5 SuspectWeld5 MaintCountReachd FeederLow UnitOnline AllGunsReady SimModeActive Std1Input31 Std1Input32 ErrorCodeBit1 ErrorCodeBit2 ErrorCodeBit4 ErrorCodeBit8 ErrorCodeBit16 ErrorCodeBit32 ErrorCodeBit64 ErrorCodeBit128 Std1Input41 Std1Input42 Std1Input43 Std1Input44 Std1Input45 Std1Input46 Std1Input47 Std1Input48 Std1Input49 Std1Input50 Std1Input51 Std1Input52 Std1Input53 Std1Input54 Std1Input55 Std1Input56 Std1Input57 Std1Input58 Std1Input59 Std1Input60 Std1Input61 Std1Input62 Std1Input63 Std1Input64

CUSW REL1.3

ROBOT OUTPUTS NORDSON DISPENSE (PS2) #1 COMMUNICATIONS NODE ADDRESS 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25

ROBOT ADDRESS DO 385 DO 386 DO 387 DO 388 DO 389 DO 390 DO 391 DO 392 DO 393 DO 394 DO 395 DO 396 DO 397 DO 398 DO 399 DO 400 DO 401 DO 402 DO 403 DO 404 DO 405 DO 406 DO 407 DO 408 DO 409 DO 410 DO 411 DO 412 DO 413 DO 414 DO 415 DO 416 DO 417 DO 418 DO 419 DO 420 DO 421 DO 422 DO 423 DO 424 DO 425 DO 426 DO 427 DO 428 DO 429 DO 430 DO 431 DO 432 DO 433 DO 434 DO 435 DO 436 DO 437 DO 438 DO 439 DO 440 DO 441 DO 442 DO 443 DO 444 DO 445 DO 446 DO 447 DO 448

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT GO[31] GO[31] GO[31] GO[31] GO[31] GO[31] GO[31] GO[31]

GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32]

SIGNAL NAME Disp1StyBit1 Disp1StyBit2 Disp1StyBit3 Disp1StyBit4 Disp1StyBit5 Disp1StyBit6 Disp1StyBit7 Disp1StyBit8 Disp1RbtinPrc Disp1StyStrobe Disp1GunON Reserved Disp1ManPurgeEnbl Reserved Reserved Reserved Disp1Complete Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Dsp1MatFlwCmdB1 Dsp1MatFlwCmdB2 Dsp1MatFlwCmdB3 Dsp1MatFlwCmdB4 Dsp1MatFlwCmdB5 Dsp1MatFlwCmdB6 Dsp1MatFlwCmdB7 Dsp1MatFlwCmdB8 Dsp1MatFlwCmdB9 Dsp1MatFlwCmdB10 Dsp1MatFlwCmdB11 Dsp1MatFlwCmdB12 Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Disp1FaultRst

AS OF 1/12/2012 Printed copies are not source controlled

ROBOT INPUTS NORDSON DISPENSE (PS2) #1 COMMUNICATIONS NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 25 DI 385 X 0.0 25 DI 386 25 DI 387 25 DI 388 25 DI 389 25 DI 390 25 DI 391 25 DI 392 25 DI 393 25 DI 394 25 DI 395 25 DI 396 25 DI 397 25 DI 398 25 DI 399 25 DI 400 25 DI 401 25 DI 402 25 DI 403 25 DI 404 25 DI 405 25 DI 406 25 DI 407 25 DI 408 25 DI 409 25 DI 410 25 DI 411 25 DI 412 25 DI 413 25 DI 414 25 DI 415 25 DI 416 25 DI 417 25 DI 418 25 DI 419 25 DI 420 25 DI 421 25 DI 422 25 DI 423 25 DI 424 25 DI 425 25 DI 426 25 DI 427 25 DI 428 25 DI 429 25 DI 430 25 DI 431 25 DI 432 25 DI 433 25 DI 434 25 DI 435 25 DI 436 25 DI 437 25 DI 438 25 DI 439 25 DI 440 25 DI 441 25 DI 442 25 DI 443 25 DI 444 25 DI 445 25 DI 446 25 DI 447 25 DI 448

28

GROUP ASSIGNMENT

SIGNAL NAME Dsp1DispenRdy Dsp1DispenInPrc Dsp1VolumeOK Reserved Reserved Reserved Reserved Reserved Dsp1LowVolFlt Dsp1HighVolFlt Dsp1LowPressFlt Dsp1HighPressFlt Dsp1ColDetd Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved

CUSW REL1.3

ROBOT OUTPUTS NORDSON DISPENSE (PS2) #2 COMMUNICATIONS NODE ADDRESS 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26

ROBOT ADDRESS DO 449 DO 450 DO 451 DO 452 DO 453 DO 454 DO 455 DO 456 DO 457 DO 458 DO 459 DO 460 DO 461 DO 462 DO 463 DO 464 DO 465 DO 466 DO 467 DO 468 DO 469 DO 470 DO 471 DO 472 DO 473 DO 474 DO 475 DO 476 DO 477 DO 478 DO 479 DO 480 DO 481 DO 482 DO 483 DO 484 DO 485 DO 486 DO 487 DO 488 DO 489 DO 490 DO 491 DO 492 DO 493 DO 494 DO 495 DO 496 DO 497 DO 498 DO 499 DO 500 DO 501 DO 502 DO 503 DO 504 DO 505 DO 506 DO 507 DO 508 DO 509 DO 510 DO 511 DO 512

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT GO[36] GO[36] GO[36] GO[36] GO[36] GO[36] GO[36] GO[36]

GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37]

SIGNAL NAME Disp2StyBit1 Disp2StyBit2 Disp2StyBit3 Disp2StyBit4 Disp2StyBit5 Disp2StyBit6 Disp2StyBit7 Disp2StyBit8 Disp2RbtinPrc Disp2StyStrobe Disp2GunON Reserved Disp2ManPurgeEnbl Reserved Reserved Reserved Disp2Complete Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Dsp2MatFlwCmdB1 Dsp2MatFlwCmdB2 Dsp2MatFlwCmdB3 Dsp2MatFlwCmdB4 Dsp2MatFlwCmdB5 Dsp2MatFlwCmdB6 Dsp2MatFlwCmdB7 Dsp2MatFlwCmdB8 Dsp2MatFlwCmdB9 Dsp2MatFlwCmdB10 Dsp2MatFlwCmdB11 Dsp2MatFlwCmdB12 Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Disp2FaultRst

AS OF 1/12/2012 Printed copies are not source controlled

ROBOT INPUTS NORDSON DISPENSE (PS2) #2 COMMUNICATIONS NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 26 DI 449 X 0.0 26 DI 450 26 DI 451 26 DI 452 26 DI 453 26 DI 454 26 DI 455 26 DI 456 26 DI 457 26 DI 458 26 DI 459 26 DI 460 26 DI 461 26 DI 462 26 DI 463 26 DI 464 26 DI 465 26 DI 466 26 DI 467 26 DI 468 26 DI 469 26 DI 470 26 DI 471 26 DI 472 26 DI 473 26 DI 474 26 DI 475 26 DI 476 26 DI 477 26 DI 478 26 DI 479 26 DI 480 26 DI 481 26 DI 482 26 DI 483 26 DI 484 26 DI 485 26 DI 486 26 DI 487 26 DI 488 26 DI 489 26 DI 490 26 DI 491 26 DI 492 26 DI 493 26 DI 494 26 DI 495 26 DI 496 26 DI 497 26 DI 498 26 DI 499 26 DI 500 26 DI 501 26 DI 502 26 DI 503 26 DI 504 26 DI 505 26 DI 506 26 DI 507 26 DI 508 26 DI 509 26 DI 510 26 DI 511 26 DI 512

29

GROUP ASSIGNMENT

SIGNAL NAME Dsp2DispenRdy Dsp2DispenInPrc Dsp2VolumeOK Reserved Reserved Reserved Reserved Reserved Dsp2LowVolFlt Dsp2HighVolFlt Dsp2LowPressFlt Dsp2HighPressFlt Dsp2ColDetd Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved

CUSW REL1.3

ROBOT OUTPUTS MH EOAT MODULE #1 OUTPUT COMMUNICATIONS (SMC)

NODE ADDRESS 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39

ROBOT ADDRESS DO 513 DO 514 DO 515 DO 516 DO 517 DO 518 DO 519 DO 520 DO 521 DO 522 DO 523 DO 524 DO 525 DO 526 DO 527 DO 528 DO 529

PMC ADDRESS K0.0 K0.1 K0.2 K0.3 K0.4 K0.5 K0.6 K0.7 K1.0 K1.1 K1.2 K1.3 K1.4 K1.5 K1.6 K1.7 K2.0

ROBOT INTERNAL ASSIGNMENT DO 10001 DO 10002 DO 10003 DO 10004 DO 10005 DO 10006 DO 10007 DO 10008 DO 10009 DO 10010 DO 10011 DO 10012 DO 10013 DO 10014 DO 10015 DO 10016 DO 10017

39

DO 530

K2.1

DO 10018

VLV9Retract

39

DO 531

K2.2

DO 10019

VLV10Extend

39

DO 532

K2.3

DO 10020

VLV10Retract

39 39 39 39 39 39 39 39 39 39 39 39

DO 533 DO 534 DO 535 DO 536 DO 537 DO 538 DO 539 DO 540 DO 541 DO 542 DO 543 DO 544

K2.4 K2.5 K2.6 K2.7 K3.0 K3.1 K3.2 K3.3 K3.4 K3.5 K3.6 K3.7

DO 10021 DO 10022 DO 10023 DO 10024 DO 10025 DO 10026 DO 10027 DO 10028 DO 10029 DO 10030 DO 10031 DO 10032

VLV11Extend VLV11Retract VLV12Extend VLV12Retract VLV13Extend VLV13Retract VLV14Extend VLV14Retract VLV15Extend VLV15Retract VLV16Extend VLV16Retract

SIGNAL NAME VLV1Extend VLV1Retract VLV2Extend VLV2Retract VLV3Extend VLV3Retract VLV4Extend VLV4Retract VLV5Extend VLV5Retract VLV6Extend VLV6Retract VLV7Extend VLV7Retract VLV8Extend VLV8Retract VLV9Extend

AS OF 1/12/2012 Printed copies are not source controlled

ROBOT INPUTS MH EOAT MODULE #1 INPUT COMMUNICATIONS

NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 31 DI 513 X 0.0 31 DI 514 31 DI 515 31 DI 516 31 DI 517 31 DI 518 31 DI 519 31 DI 520 31 DI 521 31 DI 522 31 DI 523 31 DI 524 31 DI 525 31 DI 526 31 DI 527 31 DI 528

GROUP ASSIGNMENT

SIGNAL NAME Part1Present Part2Present Part3Present Part4Present MHDev1Retracted MHDev1Extended MHDev2Retracted MHDev2Extended MHDev3Retracted MHDev3Extended MHDev4Retracted MHDev4Extended MHDev5Retracted MHDev5Extended MHDev6Retracted MHDev6Extended

ROBOT INPUTS MH EOAT MODULE #2 INPUT COMMUNICATIONS NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 32 DI 529 X 0.0 32 DI 530 32 DI 531 32 DI 532 32 DI 533 32 DI 534 32 DI 535 32 DI 536 32 DI 537 32 DI 538 32 DI 539 32 DI 540 32 DI 541 32 DI 542 32 DI 543 32 DI 544

30

GROUP ASSIGNMENT

SIGNAL NAME Part5Present Part6Present Part7Present Part8Present MHDev7Retracted MHDev7Extended MHDev8Retracted MHDev8Extended MHDev9Retracted MHDev9Extended MHDev10Retracted MHDev10Extended MHDev11Retracted MHDev11Extended MHDev12Retracted MHDev12Extended

CUSW REL1.3

ROBOT OUTPUTS ROBOT INPUTS

MH EOAT MODULE MISC OUTPUT COMMUNICATIONS (AB) COMBO EOAT VAC/CLAMPS/MISC NODE ADDRESS 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36

ROBOT ADDRESS DO 545 DO 546 DO 547 DO 548 DO 549 DO 550 DO 551 DO 552 DO 553 DO 554 DO 555 DO 556 DO 557 DO 558 DO 559 DO 560 DO 561

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

36

DO 562

User Define Output18

36

DO 563

User Define Output19

36

DO 564

User Define Output20

36 36 36 36 36 36 36 36 36 36 36 36

DO 565 DO 566 DO 567 DO 568 DO 569 DO 570 DO 571 DO 572 DO 573 DO 574 DO 575 DO 576

User Define Output21 User Define Output22 User Define Output23 User Define Output24 User Define Output25 User Define Output26 User Define Output27 User Define Output28 User Define Output29 User Define Output30 User Define Output31 User Define Output32

SIGNAL NAME User Define Output1 User Define Output2 User Define Output3 User Define Output4 User Define Output5 User Define Output6 User Define Output7 User Define Output8 User Define Output9 User Define Output10 User Define Output11 User Define Output12 User Define Output13 User Define Output14 User Define Output15 User Define Output16 User Define Output17

ROBOT OUTPUTS OUTPUT COMMUNICATIONS NODE ADDRESS

ROBOT ADDRESS DO 577

PMC ADDRESS

GROUP ASSIGNMENT

NODE ROBOT ADDRESS ADDRESS 33 DI 545 33 DI 546 33 DI 547 33 DI 548 33 DI 549 33 DI 550 33 DI 551 33 DI 552 33 DI 553 33 DI 554 33 DI 555 33 DI 556 33 DI 557 33 DI 558 33 DI 559 33 DI 560

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME Part9Present Part10Present Part11Present Part12Present MHDev13Retracted MHDev13Extended MHDev14Retracted MHDev14Extended MHDev15Retracted MHDev15Extended MHDev16Retracted MHDev16Extended MHDev17Retracted MHDev17Extended MHDev18Retracted MHDev18Extended

ROBOT INPUTS MH EOAT MODULE #4 INPUT COMMUNICATIONS NODE ROBOT ADDRESS ADDRESS 34 DI 561 34 DI 562 34 DI 563 34 DI 564 34 DI 565 34 DI 566 34 DI 567 34 DI 568 34 DI 569 34 DI 570 34 DI 571 34 DI 572 34 DI 573

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME MHDev19Retracted MHDev19Extended MHDev20Retracted MHDev20Extended MHDev21Retracted MHDev21Extended MHDev22Retracted MHDev22Extended MHDev23Retracted MHDev23Extended MHDev24Retracted MHDev24Extended MHDev25Retracted

34

DI 574

MHDev25Extended

34

DI 575

MHDev26Retracted

34

DI 576

MHDev26Extended

SIGNAL NAME Spare

DO 578

Spare

DO 579

Spare

DO 580

Spare

DO 581 DO 582 DO 583 DO 584 DO 585

Spare Spare Spare Spare Spare

ROBOT OUTPUTS SPOT TP LOGIC COMMUNICATIONS NODE ROBOT ADDRESS ADDRESS RbtInternal DO 586 RbtInternal DO 587 RbtInternal DO 588 RbtInternal DO 589 RbtInternal DO 590 RbtInternal DO 591

MH EOAT MODULE #3 INPUT COMMUNICATIONS

PMC ADDRESS Y0073.1 Y0073.2 Y0073.3 Y0073.4 Y0073.5 Y0073.6

GROUP ASSIGNMENT

SIGNAL NAME W1RstWtrSvr W1WtrOff W2RstWtrSvr W2WtrOff W1RstStepper W2RstStepper

AS OF 1/12/2012 Printed copies are not source controlled

ROBOT INPUTS MH EOAT MODULE #5 INPUT COMMUNICATIONS NODE ROBOT ADDRESS ADDRESS 35 DI 577 35 DI 578 35 DI 579 35 DI 580 35 DI 581 35 DI 582

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME MHDev27Retracted MHDev27Extended MHDev28Retracted MHDev28Extended MHDev29Retracted MHDev29Extended

35

DI 583

MHDev30Retracted

35

DI 584

MHDev30Extended

35

DI 585

MHDev31Retracted

35 35 35 35 35 35 35

DI 586 DI 587 DI 588 DI 589 DI 590 DI 591 DI 592

MHDev31Extended MHDev32Retracted MHDev32Extended MHDev33Retracted MHDev33Extended MHDev34Retracted MHDev34Extended

31

CUSW REL1.3

ROBOT OUTPUTS MH EOAT COMMUNICATIONS NODE ROBOT ADDRESS ADDRESS RbtInternal DO 592

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME MH_MAJORFLT

ROBOT OUTPUTS MH EOAT VAC MODULE #1 OUTPUT COMMUNICATIONS NODE ADDRESS 37 37 37 37 37 37 37 37

ROBOT ADDRESS DO 593 DO 594 DO 595 DO 596 DO 597 DO 598 DO 599 DO 600

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

SIGNAL NAME doVacCH1On doBlwOffCh1On doVacCH2On doBlwOffCh2On doVacCH3On doBlwOffCh3On doVacCH4On doBlwOffCh4On

ROBOT INPUTS MH EOAT VAC MODULE #1 INPUT COMMUNICATIONS NODE ROBOT ADDRESS ADDRESS 37 DI 593 37 DI 594 37 DI 595 37 DI 596 37 DI 597 37 DI 598 37 DI 599 37 DI 600

ROBOT OUTPUTS MH EOAT VAC MODULE #2 OUTPUT COMMUNICATIONS NODE ADDRESS 38 38 38 38 38 38 38 38

ROBOT ADDRESS DO 601 DO 602 DO 603 DO 604 DO 605 DO 606 DO 607 DO 608

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

SIGNAL NAME doVacCH5On doBlwOffCh5On doVacCH6On doBlwOffCh6On doVacCH7On doBlwOffCh7On doVacCH8On doBlwOffCh8On

NODE ADDRESS 43 43 43 43 43 43 43 43

ROBOT ADDRESS DO 609 DO 610 DO 611 DO 612 DO 613 DO 614 DO 615 DO 616

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

SIGNAL NAME UserDefineddo609 UserDefineddo610 UserDefineddo611 UserDefineddo612 UserDefineddo613 UserDefineddo614 UserDefineddo615 UserDefineddo616

NODE ADDRESS 44 44 44 44 44 44 44 44

ROBOT ADDRESS DO 617 DO 618 DO 619 DO 620 DO 621 DO 622 DO 623 DO 624

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

SIGNAL NAME UserDefineddo617 UserDefineddo618 UserDefineddo619 UserDefineddo620 UserDefineddo621 UserDefineddo622 UserDefineddo623 UserDefineddo624

AS OF 1/12/2012 Printed copies are not source controlled

SIGNAL NAME VacuumCH1PP VacuumCH2PP VacuumCH3PP VacuumCH4PP

ROBOT INPUTS

NODE ROBOT ADDRESS ADDRESS 38 DI 601 38 DI 602 38 DI 603 38 DI 604 38 DI 605 38 DI 606 38 DI 607 38 DI 608

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME VacuumCH5PP VacuumCH6PP VacuumCH7PP VacuumCH8PP

ROBOT INPUTS USER DEFINABLE IO #1 COMMUNICATIONS (AB) NODE ADDRESS 43 43 43 43 43 43 43 43

ROBOT ADDRESS DI 609 DI 610 DI 611 DI 612 DI 613 DI 614 DI 615 DI 616

ROBOT OUTPUTS USER DEFINABLE IO #2 COMMUNICATIONS (AB)

GROUP ASSIGNMENT

MH EOAT VAC MODULE #2 INPUT COMMUNICATIONS

ROBOT OUTPUTS USER DEFINABLE IO #1 COMMUNICATIONS (AB)

PMC ADDRESS X 0.0

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME UserDefineddi609 UserDefineddi610 UserDefineddi611 UserDefineddi612 UserDefineddi613 UserDefineddi614 UserDefineddi615 UserDefineddi616

ROBOT INPUTS USER DEFINABLE IO #2 COMMUNICATIONS (AB) NODE ADDRESS 44 44 44 44 44 44 44 44

32

ROBOT ADDRESS DI 617 DI 618 DI 619 DI 620 DI 621 DI 622 DI 623 DI 624

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME UserDefineddi617 UserDefineddi618 UserDefineddi619 UserDefineddi620 UserDefineddi621 UserDefineddi622 UserDefineddi623 UserDefineddi624

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

COMMUNICATIONS NODE ADDRESS

ROBOT ADDRESS DO 625 DO 626 DO 627 DO 628 DO 629 DO 630 DO 631

SMC PRESURE SWITCH COMMUNICATIONS PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

NODE ADDRESS 39 39 39 39 39

SIGNAL NAME Spare Spare Spare Spare Spare Spare Spare

ROBOT ADDRESS DI 625 DI 626 DI 627 DI 628 DI 629 DI 630 DI 631

ROBOT OUTPUTS

ROBOT ADDRESS DO 632 DO 633 DO 634 DO 635 DO 636 DO 637 DO 638 DO 639

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

GROUP ASSIGNMENT

SIGNAL NAME Air OK Air Acceptable range Spare Spare Spare Spare Spare

ROBOT INPUTS

ATI TOOLCHANGER COMMUNICATIONS NODE ADDRESS 54 54 54 54 54 54 54 54

PMC ADDRESS X 0.0

ATI TOOLCHANGER COMMUNICATIONS

SIGNAL NAME LatchOrLock UnlatchOrUnlock Spare ClearErrs ManualModeActd OutOfNest Spare Spare

ROBOT OUTPUTS

NODE ADDRESS 54 54 54 54 54 54 54 54 54

ROBOT ADDRESS DI 632 DI 633 DI 634 DI 635 DI 636 DI 637 DI 638 DI 639 DI 640

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME ToolLocked ToolUnLocked DNetPowerOK AuxPowerOK ReadyToLock1 ReadyToLock2 ReadyToLockV1 ReadyToLockV2 ToolStndIntlkV1

54

DI 641

ToolStndIntlkV2

ATI TOOLCHANGER (ROBOT USER DEFINED) COMM.

54

DI 642

ToolStndRelayV1

NODE ADDRESS N/A N/A N/A N/A N/A N/A

ROBOT ADDRESS DO 640 DO 641 DO 642 DO 643 DO 644 DO 645

N/A

DO 646

N/A N/A

DO 647 DO 648

N/A N/A

54

DI 643

ToolStndRelayV2

SIGNAL NAME ToolNotPresent InvalidToolRqst UnexpctdTlPrsnt NestNotEmpty NestIsEmpty GeneralFaults

54 54 54 54 54 54

DI 644 DI 645 DI 646 DI 647 DI 648 DI 649

ToolPresent ReservedTooldi13 ReservedTooldi14 ReservedTooldi15 RTLMismatch TSIVMismatch

Reference Position 11

UnCoupleToolPos1

54

DI 650

LatchOverLoad

Reference Position 12 Reference Position 13

UnCoupleToolPos2 UnCoupleToolPos3

54 54

DI 651 DI 652

UnlatchOverLoad SpareOverload

DO 649

Reference Position 14

UnCoupleToolPos4

54

DI 653

RTLrtlvMismatch

DO 650

Reference Position 15

UnCoupleToolPos5

54

DI 654

TSIVtsrvMismatch

N/A

DO 651

Reference Position 16

UnCoupleToolPos6

54

DI 655

UnsafeUnlatch

N/A N/A N/A

DO 652 DO 653 DO 654

Reference Position 17 Reference Position 18

UnCoupleToolPos7 UnCoupleToolPos8 RbtOKtoUnCouple

54 54 54 54 54

DI 656 DI 657 DI 658 DI 659 DI 660

LckUnlckSensFlt LatchNotComplt UnlatchNotComplt TSIVFault RTLFault

54

DI 661

CommError

54

DI 662

ReservedTooldi30

54

DI 663

ReservedTooldi31

54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54

DI 664 DI 665 DI 666 DI 667 DI 668 DI 669 DI 670 DI 671 DI 672 DI 673 DI 674 DI 675 DI 676 DI 677 DI 678 DI 679 DI 680 DI 681 DI 682 DI 683 DI 684

PMC ADDRESS

GROUP ASSIGNMENT

ROBOT OUTPUTS ROBOT INTERNAL COMMUNICATIONS NODE ADDRESS

ROBOT ADDRESS DO 655 DO 656 DO 657 DO 658 DO 659 DO 660 DO 661 DO 662 DO 663 DO 664 DO 665 DO 666 DO 667 DO 668 DO 669 DO 670 DO 671 DO 672 DO 673 DO 674 DO 675

PMC ADDRESS

GROUP ASSIGNMENT

AS OF 1/12/2012 Printed copies are not source controlled

SIGNAL NAME Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

33

GI[41] GI[41] GI[41] GI[41] GI[42] GI[42] GI[42] GI[42] GI[43] GI[43] GI[43] GI[43] GI[44] GI[44] GI[44] GI[44] GI[45] GI[45] GI[45] GI[45]

ToolIDswtch1bit1 ToolIDswtch1bit2 ToolIDswtch1bit4 ToolIDswtch1bit8 ToolIDswtch2bit1 ToolIDswtch2bit2 ToolIDswtch2bit4 ToolIDswtch2bit8 ToolIDswtch3bit1 ToolIDswtch3bit2 ToolIDswtch3bit4 ToolIDswtch3bit8 ToolIDSwtch4bit1 ToolIDSwtch4bit2 ToolIDSwtch4bit4 ToolIDSwtch4bit8 ToolIDSwtch5bit1 ToolIDSwtch5bit2 ToolIDSwtch5bit4 ToolIDSwtch5bit8 UnlatchEnabled

CUSW REL1.3

DO 676 DO 677 DO 678 DO 679 DO 680 DO 681 DO 682 DO 683 DO 684 DO 685 DO 686 DO 687 DO 688 DO 689 DO 690 DO 691 DO 692 DO 693 DO 694 DO 695

Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

54 54 54 54 54 54 54 54 54 54 54

DI 685 DI 686 DI 687 DI 688 DI 689 DI 690 DI 691 DI 692 DI 693 DI 694 DI 695

ROBOT OUTPUTS

ROBOT INPUTS

FORM & PIERCE MOOG COMMUNICATIONS NODE ADDRESS 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48

ROBOT ADDRESS DO 696 DO 697 DO 698 DO 699 DO 700 DO 701 DO 702 DO 703 DO 704 DO 705 DO 706 DO 707 DO 708 DO 709 DO 710 DO 711 DO 712 DO 713 DO 714 DO 715 DO 716 DO 717 DO 718 DO 719 DO 720 DO 721 DO 722 DO 723 DO 724 DO 725 DO 726 DO 727

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

ReservedTooldi53 ReservedTooldi54 ReservedTooldi55 ReservedTooldi56 ReservedTooldi57 ReservedTooldi58 ReservedTooldi59 ReservedTooldi60 ReservedTooldi61 ReservedTooldi62 ReservedTooldi63

FORM & PIERCE MOOG COMMUNICATIONS NODE ADDRESS 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48

SIGNAL NAME doDrvAReset doDrvAMode1Sel doDrvAMode2Sel doStyleDrvALub doDrvAAutomode doDrvBReset doDrvBMode1Sel doDrvBMode2Sel doStyleDrvBLub doDrvBAutomode

doDrvATorqEnble doDrvAExtPos1 doDrvARetPos2 doDrvAPosSel

doDrvBTorqEnble doDrvBExtPos1 doDrvBRetPos2 doDrvBPosSel

ROBOT ADDRESS DI 696 DI 697 DI 698 DI 699 DI 700 DI 701 DI 702 DI 703 DI 704 DI 705 DI 706 DI 707 DI 708 DI 709 DI 710 DI 711 DI 712 DI 713 DI 714 DI 715 DI 716 DI 717 DI 718 DI 719 DI 720 DI 721 DI 722 DI 723 DI 724 DI 725 DI 726 DI 727

PMC ADDRESS X 0.0

ROBOT ADDRESS DO 728 DO 729 DO 730 DO 731 DO 732 DO 733 DO 734 DO 735 DO 736 DO 737 DO 738 DO 739 DO 740 DO 741 DO 742 DO 743

PMC ADDRESS

GROUP ASSIGNMENT

AS OF 1/12/2012 Printed copies are not source controlled

SIGNAL NAME diDrvA_Ok diDrvA_On diDrvAHomeComp diDrvAForce_Lub diDrvAReturned diDrvAAtPos diDrvAMode1Ackn diDrvAMode2Ackn diSr400On diSrFuseOk

diDrvB_Ok diDrvB_On diDrvBHomeComp diDrvBForce_Lub diDrvBReturned diDrvBAtPos diDrvBMode1Ackn diDrvBMode2Ackn

ROBOT OUTPUTS

ROBOT INPUTS

FORM & PIERCE CLINCH NUT-FEEDER COMMUNICATIONS NODE ADDRESS 49 49 49 49 49 49 49 49 49 49 49 49 49 49 49 49

GROUP ASSIGNMENT

FORM & PIERCE CLINCH NUT-FEEDER COMMUNICATIONS

SIGNAL NAME doExtendPusher doReturnPusher doExtendPlunger doReturnPlunger

34

NODE ADDRESS 49 49 49 49 49 49 49 49 49 49 49 49 49 49 49 49

ROBOT ADDRESS DI 728 DI 729 DI 730 DI 731 DI 732 DI 733 DI 734 DI 735 DI 736 DI 737 DI 738 DI 739 DI 740 DI 741 DI 742 DI 743

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME diPusherExtended diPusherReturned diPlungerRetrned diPlungerExtnded diClinchAirOk diFdNutPresent

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

FORM & PIERCE CLINCH NUT-TOOL COMMUNICATIONS NODE ADDRESS 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50

ROBOT ADDRESS DO 744 DO 745 DO 746 DO 747 DO 748 DO 749 DO 750 DO 751 DO 752 DO 753 DO 754 DO 755 DO 756 DO 757 DO 758 DO 759

PMC ADDRESS

GROUP ASSIGNMENT

FORM & PIERCE CLINCH NUT-TOOL COMMUNICATIONS

SIGNAL NAME doWkSupRetract

NODE ADDRESS 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50

ROBOT ADDRESS DI 744 DI 745 DI 746 DI 747 DI 748 DI 749 DI 750 DI 751 DI 752 DI 753 DI 754 DI 755 DI 756 DI 757 DI 758 DI 759

ROBOT OUTPUTS

ROBOT ADDRESS DO 760 DO 761 DO 762 DO 763 DO 764 DO 765 DO 766 DO 767

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME doChrgAccumultor doExtIntensCyl doRetIntensCyl

NODE ADDRESS 51 51 51 51 51 51 51 51

ROBOT ADDRESS DI 760 DI 761 DI 762 DI 763 DI 764 DI 765 DI 766 DI 767

diWkAtPressure diIntensCylRetd

DI 768 DI 769 DI 770 DI 771 DI 772 DI 773 DI 774 DI 775

Complete Error Spare Spare Spare Spare Spare Spare

Laser Cut Field I/O

24 24 24 24

DO 777 DO 778 DO 779 DO 780

Release Assist Gas Spare Spare Spare Spare

24

DO 781

Spare

24

DI 781

24

DO 782

Spare

24

DI 782

24

DO 783

Spare

24

DI 783

DO 784

Spare

AS OF 1/12/2012 Printed copies are not source controlled

SIGNAL NAME diRobotAirOk

ROBOT INPUTS

Laser Cut Field I/O DO 776

GROUP ASSIGNMENT

Mig weld Reamers 46 46 46 46 46 46 46 46

Start Spray Spare Spare Spare Spare Spare Spare

ROBOT OUTPUTS

24

PMC ADDRESS

ROBOT INPUTS

Mig weld Reamers DO 768 DO 769 DO 770 DO 771 DO 772 DO 773 DO 774 DO 775

SIGNAL NAME diRbtNutPresent diWorkSptRet

FORM & PIERCE PUMP COMMUNICATIONS

ROBOT OUTPUTS 46 46 46 46 46 46 46 46

GROUP ASSIGNMENT

ROBOT INPUTS

FORM & PIERCE PUMP COMMUNICATIONS NODE ADDRESS 51 51 51 51 51 51 51 51

PMC ADDRESS

24

DI 776

Collision Sens OK

24 24 24 24

DI 777 DI 778 DI 779 DI 780

Collision Sens OK Purge Air On Purge Air Acpt Range Pre Pounce Assist Gas Pre-Pounce Assist gas Acpt Pre-Cut Assist Gas on Pre-Cut Assist Gas Acpt

DI 784

35

Spare

CUSW REL1.3

NOT USED ROBOT OUTPUTS

ROBOT INPUTS

TOOLCHANGER COVER / NEST #1 COMMUNICATIONS NODE ADDRESS 55 55 55 55 55 55 55 55

ROBOT ADDRESS DO DO DO DO DO DO DO DO

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

TOOLCHANGER COVER / NEST #1 COMMUNICATIONS

SIGNAL NAME Close Cover #1 Open Cover #1

NODE ADDRESS 55 55 55 55 55 55 55 55

ROBOT ADDRESS DI DI DI DI DI DI DI DI

ROBOT OUTPUTS ROBOT ADDRESS DO DO DO DO DO DO DO DO

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

SIGNAL NAME Close Cover #2 Open Cover #2

NODE ADDRESS 56 56 56 56 56 56 56 56

ROBOT ADDRESS DI DI DI DI DI DI DI DI

ROBOT OUTPUTS ROBOT ADDRESS DO DO DO DO DO DO DO DO

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

AS OF 1/12/2012 Printed copies are not source controlled

GROUP ASSIGNMENT

SIGNAL NAME Cover #2 Closed Cover #2 Open Tool in nest #2 switch 1 Tool in nest #2 switch 2

ROBOT INPUTS

SIGNAL NAME Close Cover #3 Open Cover #3

NODE ADDRESS 57 57 57 57 57 57 57 57

ROBOT ADDRESS DI DI DI DI DI DI DI DI

ROBOT OUTPUTS ROBOT ADDRESS DO DO DO DO DO DO DO DO

PMC ADDRESS X 0.0

TOOLCHANGER COVER / NEST #3 COMMUNICATIONS PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME Cover #3 Closed Cover #3 Open Tool in nest #3 switch 1 Tool in nest #3 switch 2

ROBOT INPUTS

TOOLCHANGER COVER / NEST #4 COMMUNICATIONS NODE ADDRESS 58 58 58 58 58 58 58 58

SIGNAL NAME Cover #1 Closed Cover #1 Open Tool in nest #1 switch 1 Tool in nest #1 switch 2

TOOLCHANGER COVER / NEST #2 COMMUNICATIONS

TOOLCHANGER COVER / NEST #3 COMMUNICATIONS NODE ADDRESS 57 57 57 57 57 57 57 57

GROUP ASSIGNMENT

ROBOT INPUTS

TOOLCHANGER COVER / NEST #2 COMMUNICATIONS NODE ADDRESS 56 56 56 56 56 56 56 56

PMC ADDRESS X 0.0

TOOLCHANGER COVER / NEST #4 COMMUNICATIONS

SIGNAL NAME Close Cover #4 Open Cover #4

36

NODE ADDRESS 58 58 58 58 58 58 58 58

ROBOT ADDRESS DI DI DI DI DI DI DI DI

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME Cover #4 Closed Cover #4 Open Tool in nest #4 switch 1 Tool in nest #4 switch 2

CUSW REL1.3

ROBOT OUTPUTS IPG_Laserweld_Generator NODE ADDRESS 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17

ROBOT ADDRESS DO 785 DO 786 DO 787 DO 788 DO 789 DO 790 DO 791 DO 792 DO 793 DO 794 DO 795 DO 796 DO 797 DO 798 DO 799 DO 800 DO 801 DO 802 DO 803 DO 804 DO 805 DO 806 DO 807 DO 808 DO 809 DO 810 DO 811 DO 812 DO 813 DO 814 DO 815 DO 816

PMC ADDRESS

ROBOT INPUTS IPG_Laserweld_Generator

GROUP ASSIGNMENT

SIGNAL NAME doLasrRequest doLasrProgStart doLasrEnbPCCtrl doLasrReset doGuideLaserCtrl doLasrAnalogCtrl doLasrProgStop doLasrProgLSB doLasrProg1 doLasrProg2 doLasrProg3 doLasrProg4 doLasrProg5 doLasrProgMSB doLasrSyncInput doLasrReserve Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

NODE ROBOT ADDRESS ADDRESS 17 DI 785 17 DI 786 17 DI 787 17 DI 788 17 DI 789 17 DI 790 17 DI 791 17 DI 792 17 DI 793 17 DI 794 17 DI 795 17 DI 796 17 DI 797 17 DI 798 17 DI 799 17 DI 800 DI 801 DI 802 DI 803 DI 804 DI 805 DI 806 DI 807 DI 808 DI 809 DI 810 DI 811 DI 812 DI 813 DI 814 DI 815 DI 816

ROBOT OUTPUTS HighYag NODE ADDRESS 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME diLasrReady diLasrEmissionOn diLasrIntrCtrlOn diLasrError diGuideLaserOn diLasrAnalogCtrl diLasrAssigned diLasrOn diLasrProgActive diLasrProgEnd diLasrProgIntrpt diLasrSyncOutput diLasrWarning diLasrChillWarn diLasrChillError diLasrChillReady Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

ROBOT INPUTS HighYag

ROBOT ADDRESS DO 817 DO 818 DO 819 DO 820 DO 821 DO 822 DO 823 DO 824 DO 825 DO 826 DO 827 DO 828 DO 829 DO 830 DO 831 DO 832 DO 833 DO 834 DO 835 DO 836 DO 837 DO 838 DO 839 DO 840 DO 841 DO 842 DO 843 DO 844 DO 845 DO 846 DO 847 DO 848

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME doHYagTriggerA doHYagProcError doHYagLaserError doHYagRestScannr doHYagPSelPart doHYagPSelRbtTrx doHYagPSelTrxPt doHYagPSelSeam doHYagPSelRbtVel doHYagModeBit0 doHYagModeBit1 doHYagModeBit2 doHYagC-JetOnOff doHYagReserve doHYagNumBit0 doHYagNumBit1 doHYagNumBit2 doHYagNumBit3 doHYagNumBit4 doHYagNumBit5 doHYagNumBit6 doHYagNumBit7 Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

AS OF 1/12/2012 Printed copies are not source controlled

NODE ROBOT ADDRESS ADDRESS 18 DI 817 18 DI 818 18 DI 819 18 DI 820 18 DI 821 18 DI 822 18 DI 823 18 DI 824 18 DI 825 18 DI 826 18 DI 827 18 DI 828 18 DI 829 18 DI 830 18 DI 831 18 DI 832 18 DI 833 18 DI 834 18 DI 835 18 DI 836 18 DI 837 18 DI 838 18 DI 839 18 DI 840 18 DI 841 18 DI 842 18 DI 843 18 DI 844 18 DI 845 18 DI 846 18 DI 847 18 DI 848

37

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME diHYagScanAvail diHYagScanRdy diHYagScanMonitr diHYagGenError diHYagStructErr diHYagScanAtWork diHYagSlideHoldr diHYagSlideWarn diHYagSlideError diHYagPosError diHYagTempError diHYagC-JetError diHYagEnetActive Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

LaserCut Head NODE ADDRESS 19 19 19 19 19 19 19 19

LaserCut Head

ROBOT ADDRESS DO 849 DO 850 DO 851 DO 852 DO 853 DO 854 DO 855 DO 856

PMC ADDRESS

GROUP ASSIGNMENT GO(46] GO[46] GO[46]

SIGNAL NAME HeightSelBit1 HeightSelBit2 HeightSelBit3 Tch/CtrOfTrvl MotInhbt/Hold TipSelBit AnalogInEnbl Reset

NODE ADDRESS 19 19 19 19 19 19 19 19

ROBOT ADDRESS DI 849 DI 850 DI 851 DI 852 DI 853 DI 854 DI 855 DI 856

ROBOT OUTPUTS ROBOT ADDRESS DO 857 DO 858 DO 859 DO 860 DO 861 DO 862 DO 863 DO 864

PMC ADDRESS

GROUP ASSIGNMENT GO[47] GO[47] GO[47] GO[47] GO[48] GO[48] GO(48]

SIGNAL NAME ACT/RET SetActiveRetract ComdFourceLevBit0 ComdFourceLevBit1 ComdFourceLevBit2 ComdFourceLevBit3 ToolNumBit0 ToolNumBit1 ToolNumBit2

NODE ADDRESS 20 20 20 20 20 20 20 20

ROBOT ADDRESS DI 857 DI 858 DI 859 DI 860 DI 861 DI 862 DI 863 DI 864

ROBOT OUTPUTS

GROUP ASSIGNMENT GI[47] GI[47] GI[47] GI[47]

SIGNAL NAME ForceFedbackBit0 ForceFedbackBit1 ForceFedbackBit2 ForceFedbackBit3 PlusLimit MinusLimit Spare Spare

ROBOT INPUTS

ROBOT ADDRESS DO 865 DO 866 DO 867 DO 868 DO 869 DO 870 DO 871 DO 872

PMC ADDRESS

GROUP ASSIGNMENT GO[49] GO[49] GO[49] GO[49]

SIGNAL NAME Spare UserInputBit0 UserInputBit1 UserInputBit2 UserInputBit3 Spare SpindleEnable Spare

NODE ADDRESS 21 21 21 21 21 21 21 21

ROBOT ADDRESS DI 865 DI 866 DI 867 DI 868 DI 869 DI 870 DI 871 DI 872

ROBOT OUTPUTS ROBOT ADDRESS AO 1, 1-16 AO 2, 1-16 AO 3, 1-16 AO 4, 1-16

PMC ADDRESS

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME Spare Spare Spare Spare Spare Spare CRF Fault Spare

ROBOT INPUTS

GROUP ASSIGNMENT

SIGNAL NAME CommandForce Spare Spare AMPThermister Spare Spare Spare Spare

NODE ADDRESS 22 22 22 22

ROBOT ADDRESS AI 1, 1-16 AI 2, 1-16 AI 3, 1-16 AI 4, 1-16

ROBOT OUTPUTS

ROBOT ADDRESS AO 5, 1-16 AO 6, 1-16 AO 7, 1-16 AO 8, 1-16

PMC ADDRESS

GRINDING ANALOG MODULE #1 PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME ActualForce CarriagePos Spare Spare Spare Spare Spare Spare

ROBOT INPUTS

GRINDING ANALOG MODULE #2 NODE ADDRESS 23 23 23 23

PMC ADDRESS

GrinderMod2

GRINDING ANALOG MODULE #1 NODE ADDRESS 22 22 22 22

GI[46] GI[46] GI[46] GI[46]

SIGNAL NAME InPosition RetdPos TipTouch Crsh/FltActive StatCode1 StatCode2 StatCode3 StatCode4

GrinderMod1

GrinderMod2 NODE ADDRESS 21 21 21 21 21 21 21 21

GROUP ASSIGNMENT

ROBOT INPUTS

GrinderMod1 NODE ADDRESS 20 20 20 20 20 20 20 20

PMC ADDRESS

GRINDING ANALOG MODULE #2 GROUP ASSIGNMENT

DO 889 DO 890 DO 891 DO 892 DO 893 DO 894 DO 895 DO 896 DO 897

AS OF 1/12/2012 Printed copies are not source controlled

SIGNAL NAME VelCommand Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

NODE ADDRESS 23 23 23 23

ROBOT ADDRESS AI 5, 1-16 AI 6, 1-16 AI 7, 1-16 AI 8, 1-16

DI 889 DI 890 DI 891 DI 892 DI 893 DI 894 DI 895 DI 896 DI 897

38

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME VelMon CurrentRef Spare CurrentMon Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

CUSW REL1.3

DO 898 DO 899 DO 900 DO 901 DO 902 DO 903

Spare Spare Spare Spare Spare Spare

DI 898 DI 899 DI 900 DI 901 DI 902 DI 903

Spare Spare Spare Spare Spare Spare

DO 904

Spare

DI 904

Spare

DO 905 DO 906 DO 907 DO 908 DO 909 DO 910 DO 911 DO 912

Spare Spare Spare Spare Spare Spare Spare Spare

DI 905 DI 906 DI 907 DI 908 DI 909 DI 910 DI 911 DI 912

Spare Spare Spare Spare Spare Spare Spare Spare

ROBOT OUTPUTS

ROBOT INPUTS

ISRA VISION COMMUNICATIONS NODE ADDRESS 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60

ROBOT ADDRESS DO 913 DO 914 DO 915 DO 916 DO 917 DO 918 DO 919 DO 920 DO 921 DO 922 DO 923 DO 924 DO 925 DO 926 DO 927 DO 928 DO 929 DO 930 DO 931 DO 932 DO 933 DO 934 DO 935 DO 936 DO 937 DO 938 DO 939 DO 940 DO 941 DO 942 DO 943 DO 944

PMC ADDRESS Y 0.0

ISRA VISION COMMUNICATIONS GROUP ASSIGNMENT GO[38] GO[38] GO[38] GO[38]

GO[40] GO[39] GO[39] GO[39] GO[39] GO[39] GO[39] GO[39] GO[39] GO[41] GO[41] GO[41] GO[41] GO[41] GO[41] GO[41] GO[41] GO[42] GO[42] GO[42] GO[42] GO[42] GO[42] GO[42] GO[42]

SIGNAL NAME doISRA_CmdB1 doISRA_CmdB2 doISRA_CmdB4 doISRA_CmdB8 doISRA_Strt_M doISRA_reservd doISRA_Rst_E doISRA_ID_Valid doISRA_TpIDB1 doISRA_TpIDB2 doISRA_TpIDB4 doISRA_TpIDB8 doISRA_TpIDB16 doISRA_TpIDB32 doISRA_TpIDB64 doISRA_TpIDB128 doISRA_SubStyle doISRA_SubStyle doISRA_SubStyle doISRA_SubStyle doISRA_SubStyle doISRA_SubStyle doISRA_SubStyle doISRA_SubStyle doISRA_Color doISRA_Color doISRA_Color doISRA_Color doISRA_Color doISRA_Color doISRA_Color doISRA_Color

ROBOT OUTPUTS APP. ERROR CODE (ROBOT USER DEFINED) COMM. NODE ADDRESS N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

ROBOT ADDRESS DO 945 DO 946 DO 947 DO 948 DO 949 DO 950 DO 951 DO 952 DO 953 DO 954 DO 955 DO 956 DO 957 DO 958 DO 959 DO 960 DO 961 DO 962 DO 963

PMC ADDRESS

GROUP ASSIGNMENT N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

AS OF 1/12/2012 Printed copies are not source controlled

SIGNAL NAME AppErrSpare01 AppErrSpare02 AppErrSpare03 AppErrSpare04 AppErrSpare05 AppErrSpare06 AppErrSpare07 AppErrSpare08 AppErrSpare09 AppErrSpare10 AppErrSpare11 AppErrSpare12 AppErrSpare13 AppErrSpare14 AppErrSpare15 AppErrSpare16 AppErrSpare17 AppErrSpare18 AppErrSpare19

39

NODE ADDRESS 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60

ROBOT ADDRESS DI 913 DI 914 DI 915 DI 916 DI 917 DI 918 DI 919 DI 920 DI 921 DI 922 DI 923 DI 924 DI 925 DI 926 DI 927 DI 928 DI 929 DI 930 DI 931 DI 932 DI 933 DI 934 DI 935 DI 936 DI 937 DI 938 DI 939 DI 940 DI 941 DI 942 DI 943 DI 944 DI 945

60 60

PMC ADDRESS X 0.0

GROUP ASSIGNMENT GI[31] GI[31] GI[31] GI[31]

GI[38] GI[38] GI[38] GI[38] GI[38] GI[38] GI[38] GI[38] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[33]

SIGNAL NAME diISRA_StatBit1 diISRA_StatBit2 diISRA_StatBit4 diISRA_StatBit8 diISRA_Ready diISRA_Snap_ip diISRA_Data_ip diISRA_ID_OK diISRA_reservd diISRA_ErrPLC diISRA_ErrRbt diISRA_OutTol diISRA_Disabl diISRA_ErrImage diISRA_reservd1 diISRA_ErrDet diISRA_XB1 diISRA_XB2 diISRA_XB4 diISRA_XB8 diISRA_XB16 diISRA_XB32 diISRA_XB64 diISRA_XB128 diISRA_XB256 diISRA_XB512 diISRA_XB1024 diISRA_XB2048 diISRA_XB4096 diISRA_XB8192 diISRA_XB16384 diISRA_XB32768 diISRA_YB1

DI 946

GI[33]

diISRA_YB2

DI 947

GI[33]

diISRA_YB4

60

DI 948

GI[33]

diISRA_YB8

60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60

DI 949 DI 950 DI 951 DI 952 DI 953 DI 954 DI 955 DI 956 DI 957 DI 958 DI 959 DI 960 DI 961 DI 962 DI 963 DI 964 DI 965 DI 966 DI 967

GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34]

diISRA_YB16 diISRA_YB32 diISRA_YB64 diISRA_YB128 diISRA_YB256 diISRA_YB512 diISRA_YB1024 diISRA_YB2048 diISRA_YB4096 diISRA_YB8192 diISRA_YB16384 diISRA_YB32768 diISRA_ZB1 diISRA_ZB2 diISRA_ZB4 diISRA_ZB8 diISRA_ZB16 diISRA_ZB32 diISRA_ZB64

CUSW REL1.3

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

DO 964 DO 965 DO 966 DO 967 DO 968 DO 969 DO 970 DO 971 DO 972 DO 973 DO 974 DO 975 DO 976 DO 977 DO 978 DO 979 DO 980 DO 981 DO 982 DO 983 DO 984 DO 985 DO 986 DO 987 DO 988 DO 989 DO 990 DO 991 DO 992 DO 993 DO 994 DO 995 DO 996 DO 997 DO 998 DO 999 DO 1000 DO 1001 DO 1002 DO 1003 DO 1004 DO 1005 DO 1006 DO 1007 DO 1008 DO 1009 DO 1010 DO 1011 DO 1012 DO 1013 DO 1014 DO 1015 DO 1016 DO 1017 DO 1018 DO 1019 DO 1020 DO 1021 DO 1022 DO 1023 DO 1024

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

AppErrSpare20 AppErrSpare21 AppErrSpare22 AppErrSpare23 AppErrSpare24 AppErrSpare25 AppErrSpare26 AppErrSpare27 AppErrSpare28 AppErrSpare29 AppErrSpare30 AppErrSpare31 AppErrSpare32 AppErrSpare33 AppErrSpare34 AppErrSpare35 AppErrSpare36 AppErrSpare37 AppErrSpare38 AppErrSpare39 AppErrSpare40 AppErrSpare41 AppErrSpare42 AppErrSpare43 AppErrSpare44 AppErrSpare45 AppErrSpare46 AppErrSpare47 AppErrSpare48 AppErrSpare49 AppErrSpare50 AppErrSpare51 AppErrSpare52 AppErrSpare53 AppErrSpare54 AppErrSpare55 AppErrSpare56 AppErrSpare57 AppErrSpare58 AppErrSpare59 AppErrSpare60 AppErrSpare61 AppErrSpare62 AppErrSpare63 AppErrSpare64 AppErrSpare65 AppErrSpare66 AppErrSpare67 AppErrSpare68 AppErrSpare69 AppErrSpare70 AppErrSpare71 AppErrSpare72 AppErrSpare73 AppErrSpare74 AppErrSpare75 AppErrSpare76 AppErrSpare77 AppErrSpare78 AppErrSpare79 AppErrSpare80

60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60

DI 968 DI 969 DI 970 DI 971 DI 972 DI 973 DI 974 DI 975 DI 976 DI 977 DI 978 DI 979 DI 980 DI 981 DI 982 DI 983 DI 984 DI 985 DI 986 DI 987 DI 988 DI 989 DI 990 DI 991 DI 992 DI 993 DI 994 DI 995 DI 996 DI 997 DI 998 DI 999 DI 1000 DI 1001 DI 1002 DI 1003 DI 1004 DI 1005 DI 1006 DI 1007 DI 1008 DI 1009 DI 1010 DI 1011 DI 1012 DI 1013 DI 1014 DI 1015 DI 1016 DI 1017 DI 1018 DI 1019 DI 1020 DI 1021 DI 1022 DI 1023 DI 1024

ROBOT OUTPUTS

ROBOT ADDRESS DO 901 DO 902 DO 903 DO 904 DO 905 DO 906 DO 907 DO 908 DO 909 DO 910 DO 911 DO 912

PMC ADDRESS

diISRA_ZB128 diISRA_ZB256 diISRA_ZB512 diISRA_ZB1024 diISRA_ZB2048 diISRA_ZB4096 diISRA_ZB8192 diISRA_ZB16384 diISRA_ZB32768 diISRA_RXB1 diISRA_RXB2 diISRA_RXB4 diISRA_RXB8 diISRA_RXB16 diISRA_RXB32 diISRA_RXB64 diISRA_RXB128 diISRA_RXB256 diISRA_RXB512 diISRA_RXB1024 diISRA_RXB2048 diISRA_RXB4096 diISRA_RXB8192 diISRA_RXB16384 diISRA_RXB32768 diISRA_RYB1 diISRA_RYB2 diISRA_RYB4 diISRA_RYB8 diISRA_RYB16 diISRA_RYB32 diISRA_RYB64 diISRA_RYB128 diISRA_RYB256 diISRA_RYB512 diISRA_RYB1024 diISRA_RYB2048 diISRA_RYB4096 diISRA_RYB8192 diISRA_RYB16384 diISRA_RYB32768 diISRA_RZB1 diISRA_RZB2 diISRA_RZB4 diISRA_RZB8 diISRA_RZB16 diISRA_RZB32 diISRA_RZB64 diISRA_RZB128 diISRA_RZB256 diISRA_RZB512 diISRA_RZB1024 diISRA_RZB2048 diISRA_RZB4096 diISRA_RZB8192 diISRA_RZB16384 diISRA_RZB32768

ROBOT INPUTS

ROBOT INTERNAL COMMUNICATIONS NODE ADDRESS RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal

GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37]

ROBOT INTERNAL COMMUNICATIONS GROUP ASSIGNMENT

AS OF 1/12/2012 Printed copies are not source controlled

SIGNAL NAME WaterValve1ON WaterValve1OFF WaterValve2ON WaterValve2OFF VacuumCH_ON PulseBatteryLow XFORMTEMPOk1 XFORMTEMPOk2 XFORMTEMPOk3 XFORMTEMPOk4

40

NODE ADDRESS RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal RbtInternal

ROBOT ADDRESS DI 901 DI 902 DI 903 DI 904 DI 905 DI 906 DI 907 DI 908 DI 909 DI 910 DI 911 DI 912

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME WaterFlowOK1 WaterFlowOK2

VacuumCH_ON XFORMTEMPOk1 XFORMTEMPOk2 XFORMTEMPOk3 XFORMTEMPOk4

CUSW REL1.3

ROBOT APPLICATION ERROR TIMING

SYNCHRONIZE PLC / IDENTIFY TOP OF PMC LOGIC Application Error Bits (Group Output)

GO[4] = FIS ID DO[121 – 128]

LOW State Error Active goes LOW when Error Ack goes HIGH

Application Error Active

DO[120]

LOOP Until ALL Application Errors (if applicable) is monitored

LOOP Until ALL Application Errors (if applicable) is monitored

Application Error Acknowledge (PLC Signal)

Error Ack goes LOW when Error Active goes LOW

DI[8]

ADDING APPLICATION ERROR BITS TO PLC Application Error Bits (Group Output)

GO[4] = FIS ID DO[121 – 128]

a Application Error Active

Error Active goes LOW when Error Ack goes HIGH

Application Error Acknowledge (PLC Signal)

Error Ack goes LOW when Error Active goes LOW

DO[120]

DI[8]

REMOVING APPLICATION ERROR BITS FROM PLC Application Error Bits (Group Output)

GO[4] = FIS ID DO[121 – 128]

Application Error Remove

Error Active goes LOW when Error Ack goes HIGH DO[76] a

Application Error Active

Error Active goes LOW when Error Ack goes HIGH b

b

Application Error Acknowledge (PLC Signal)

Error Ack goes LOW when Error Active goes LOW

DO[120]

DI[8]

a = 500 msec

ROBOT INPUTS FROM PLC

AS OF 1/12/2012 Printed copies are not source controlled

ROBOT OUTPUTS TO PLC

41

Not Robot I/O

CUSW REL1.3

ROBOT APPLICATION ERRORS INPUT/S

GROUP INPUT

N/A

N/A

DESCRIPTION

ERROR PLC SEVERITY CODE

IO STATE

INTERNAL ROBOT HANDSHAKE TO PLC Clear all faults command ID

N/A

0

N/A

SPARE General Communication DeviceNet Master

Major

Low Battery Indicator

Minor

1 2 3 4

CLINCH NUT No Nut In Anvil Feeder Air Not On Clinch Nut Still in Anvil Clinch Nut Not Present at Feeder Nut Feeder Plunger Not In Position Clinch Nut Part Present Fault Nut Feeder Pusher Not In Position

5 6 7 8 9 10 11

NET-FORM-PIERCE Work Support Pressure Fault Moog Mode Fault Moog Drive A OK Fault Moog Drive B OK Fault Moog Drive A ON Fault Moog Drive B ON Fault Moog Drive A Position Fault Moog Drive B Position Fault Moog Drive A Force Fault Moog Drive B Force Fault

12 13 14 15 16 17 18 19 20 21

QMC/FMS AAC Error AAC Required ATC Error ATC Required ATC Expired Vision Comm Heartbeat Lost Vision System App Fault

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42

Major Major Major Major Major Major Major

22 23 24 25 26 27 28 29 30 31 32

CUSW REL1.3

INPUT/S

GROUP INPUT

DI 197 -201 DI 229 -233

GI[11] GI[13]

I/O Error

Major/Minor

33

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

I/O Alarm

Major/Minor

34

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Incomplete Weld

Major/Minor

35

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Stepper Approaching Max

Major/Minor

36

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

End Of Stepper

Major/Minor

37

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Sure Weld Trend Limit

Major/Minor

38

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

High/Low Current Limit

Major/Minor

39

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Firing Error

Major/Minor

40

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Cylinder Fault

Major/Minor

41

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Cylinder Alarm

Major/Minor

42

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Power Factor Error

Major/Minor

43

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Compensation Error

Major/Minor

44

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Insufficient Line Voltage

Major/Minor

45

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Extend Weld

Major/Minor

46

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Isolation Contactor Error

Major/Minor

47

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Welding Buss Voltage

Major/Minor

48

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Weld Data Not Programmed

Major/Minor

49

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Analog Pressure Error

Major/Minor

50

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

C-Factor Limit

Major/Minor

51

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Secondary Current

Major/Minor

52

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Welding Transformer

Major/Minor

53

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Over Temperature

Major/Minor

54

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Shorted SCR

Major/Minor

55

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Internal Timer Error

Major/Minor

56

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Inverter Fault

Major/Minor

57

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Timer Not Ready

Major/Minor

58

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Reserved

Major/Minor

59

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Reserved

Major/Minor

60

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Reserved

Major/Minor

61

N/A

DESCRIPTION

ERROR PLC SEVERITY CODE

IO STATE

SPOTWELDING

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43

CUSW REL1.3

INPUT/S

GROUP INPUT

DI 197 -201 DI 229 -233

GI[11] GI[13]

Reserved

Major/Minor

62

N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Reserved

Major/Minor

63

N/A

DI 785 DI 787

N/A N/A

Major

64 65

N/C N/O

DI 817 DI 819

N/A N/A

66 67

N/C N/O

DESCRIPTION

ERROR PLC SEVERITY CODE

IO STATE

WATER SAVER W1OKtoWeld

WELD SERVOGUN / ARC N/A N/A N/A N/A N/A N/A N/A N/A N/A

ServoGun Faulted

N/A

Transformer over temperature

DO 640 DO 641 DI 648 DI 649 DI 650 DI 651 DI 652 DI 653 DI 654 DI 655 DI 656 DI 657 DI 658 DI 659 DI 660 DI 661 DI 684 DI 634 DI 635 DO 642 DO 643 DO 644

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

ToolNotPresent Invalid Tool Requested RTLMismatch TSIVMismatch LatchOverLoad UnlatchOverLoad SpareOverload RTLrtlvMismatch TSIVtsrvMismatch UnsafeUnlatch LckUnlckSensFlt LatchNotComplt UnlatchNotComplt TSIVFault RTLFault Comm Error Unlatch Enabled DNetPowerNotPresent

DI 321 DI 326 DI 331 DI 336 DI 341 DI 347 DI 348 DI 349

N/A N/A N/A N/A N/A N/A N/A N/A

NOError1 NOError2 NOError3 NOError4 NOError5 Std1StudsLow Std1ReadyForAuto Std1ReadyToWeld

SPOT-068 ARC-006 ARC-008 ARC-010 ARC-013 ARC-017 ARC-018 ARC-030 ARC-033

68 69 70 71 72 73 74 75 76

Wire Fault Power Supply Fault Wire stick detected Arc Start failed Arc Start was Disabled Lost arc detect Wire stick is still detected Override must be 100% to weld

INTERNAL ROBOT Major

77

TOOL CHANGER

AuxPowerNotPresent Unexpected Tool Present Nest not empty Nest is empty

78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99

N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/C N/O N/O N/O N/O N/O

100 101 102 103 104 105 106 107

N/C N/C N/C N/C N/C N/O N/O N/C

STUD WELDING

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Major Major Major Major Major Minor Major Major

44

CUSW REL1.3

SPARE 108 109 110 111 112 113 114 115 116 117 118 119

NORDSON DISPENSING #1

DI 393 DI 394 DI397 Di395 DI396

N/A N/A N/A N/A N/A

Nozzle 1 Low Volume Fault Nozzle 1 High Volume Fault Nozzle 1 Collision Detected Dispense 1 Low Pressure Fault Dispense 1 High Pressure Fault

Major Major Major Major Major

120 121 122 123 124 125 126 127 128 129

N/O N/O N/O N/O N/O

NORDSON DISPENSING #2

DI 457 DI 458 DI461 DI459 DI460

N/A N/A N/A N/A N/A

Nozzle 2 Low Volume Fault Nozzle 2 High Volume Fault Nozzle 2 Collision Detected Dispense 2 Low Pressure Fault Dispense 2 High Pressure Fault

Major Major Major Major Major

130 131 132 133 134 135 136 137 138 139 140

N/O N/O N/O N/O N/O

PERCEPTRON VISION Perceptron Communication Fault Perceptron Status Fault Perceptron Bad Measurement General Search Error

Major Major Major Major

141 142 143 144 145

N/O N/O N/O N/O

Major Major

146 147

N/O N/O

DYNALOG MEASUREMENT Dynalog Major Fault Dynalog Minor Fault

SPARE 148 149 150

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45

CUSW REL1.3

ISRA VISION DI 917 DI 918 DI 919 DI 920 DI 922 DI 923 DI 924 DI 925 DI 926 DI 928

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

diISRA_Ready diISRA_Meas_ip diISRA_Data_ip diISRA_ID_OK diISRA_ErrPLC diISRA_ErrRbt diISRA_OutTol diISRA_Disabl diISRA_ErrImage diISRA_ErrDet

Major Major Major Major Major Major Major Major Major Major

150 151 152 153 154 155 156 157 158 159

MATERIAL HANDLING/VISION Rack not open fault Part search fault

Major Major

160 161

Minor Minor

162 163

N/O N/O

TRACK LUBE Track Bearing Lube Fault Track Pinion Lube Fault

MATERIAL HANDLING N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

VacuumCH1PP Fault VacuumCH2PP Fault VacuumCH3PP Fault VacuumCH4PP Fault VacuumCH5PP Fault VacuumCH6PP Fault VacuumCH7PP Fault VacuumCH8PP Fault VacuumCH9PP Fault VacuumCH10PP Fault VacuumCH11PP Fault VacuumCH12PP Fault Part Present 1 Fault Part Present 2 Fault Part Present 3 Fault Part Present 4 Fault Part Present 5 Fault Part Present 6 Fault Part Present 7 Fault Part Present 8 Fault Part Present 9 Fault Part Present 10 Fault Part Present 11 Fault Part Present 12 Fault MH Device 1 Retract Fault MH Device 2 Retract Fault MH Device 3 Retract Fault MH Device 4 Retract Fault MH Device 5 Retract Fault MH Device 6 Retract Fault MH Device 7 Retract Fault MH Device 8 Retract Fault MH Device 9 Retract Fault MH Device 10 Retract Fault MH Device 11 Retract Fault MH Device 12 Retract Fault MH Device 13 Retract Fault MH Device 14 Retract Fault MH Device 15 Retract Fault

AS OF 1/12/2012 Printed copies are not source controlled

Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor

46

164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202

EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN

CUSW REL1.3

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

MH Device 16 Retract Fault MH Device 17 Retract Fault MH Device 18 Retract Fault MH Device 19 Retract Fault MH Device 20 Retract Fault MH Device 21 Retract Fault MH Device 22 Retract Fault MH Device 23 Retract Fault MH Device 24 Retract Fault MH Device 25 Retract Fault MH Device 26 Retract Fault MH Device 27 Retract Fault MH Device 28 Retract Fault MH Device 29 Retract Fault MH Device 30 Retract Fault MH Device 31 Retract Fault MH Device 32 Retract Fault MH Device 33 Retract Fault MH Device 34 Retract Fault MH Device 1 Extend Fault MH Device 2 Extend Fault MH Device 3 Extend Fault MH Device 4 Extend Fault MH Device 5 Extend Fault MH Device 6 Extend Fault MH Device 7 Extend Fault MH Device 8 Extend Fault MH Device 9 Extend Fault MH Device 10 Extend Fault MH Device 11 Extend Fault MH Device 12 Extend Fault MH Device 13 Extend Fault MH Device 14 Extend Fault MH Device 15 Extend Fault MH Device 16 Extend Fault MH Device 17 Extend Fault MH Device 18 Extend Fault MH Device 19 Extend Fault MH Device 20 Extend Fault MH Device 21 Extend Fault MH Device 22 Extend Fault MH Device 23 Extend Fault MH Device 24 Extend Fault MH Device 25 Extend Fault MH Device 26 Extend Fault MH Device 27 Extend Fault MH Device 28 Extend Fault MH Device 29 Extend Fault MH Device 30 Extend Fault MH Device 31 Extend Fault MH Device 32 Extend Fault MH Device 33 Extend Fault MH Device 34 Extend Fault

Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor

203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255

EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN

Note: If a Material Handling Fault is disabled using the DF&C function, the appropriate application error bit will be posted as a MINOR fault indicating that the MAJOR fault is disabled. The Process Fault bit will remain low.

AS OF 1/12/2012 Printed copies are not source controlled

47

CUSW REL1.3

PLC LOGIC REFERENCE The 12PF program will utilize Allen-Bradley GuardLogix Processors with DeviceNet for PLC to Robot and Robot to PLC communications. Please reference the latest 12PF Library, distributed by DCX Controls Coordinators, for the robot related modules.

AS OF 1/12/2012 Printed copies are not source controlled

48

CUSW REL1.3

ROBOT PROGRAM NAMING Robot program names shall follow the convention described by the table below:

Table 1. Program Names Style # Programs

Program Name (8 char. max)

Comment (16 char. max)

Program Description

1

STYLE001

Maint Style 1

(Maintenance Program) - User Specified

2

STYLE002

WeldGunForceChck

User Specified - Weld Gun Force Check

3

STYLE003

Tip Change

(Maintenance Program) - Executes motion and/or macro calls required to change the tips on the weld gun

4

STYLE004

Purge

(Maintenance Program) - Executes motion and/or macro calls required to purge the dispense gun

5

STYLE005

Tip Burn In

(Maintenance Program) - Executes motion and/or macro calls required to burn in the tips on the weld gun

6

STYLE006

Service Program

(Maintenance Program) - Executes motion and/or macro calls required to move the robot to the service position

7

STYLE007

TipDress 1st Gun / Tip1BurnIN

(Maintenance Program) - Executes motion and/or macro calls required to dress the tips on the 1st gun

8

STYLE008

TipDress 2nd Gun / Tip2BurnIN

(Maintenance Program) - Executes motion and/or macro calls required to dress the tips on the 2nd gun

9

STYLE009

Tool Change

(Maintenance Program) - Executes motion and/or macro calls required to change the tool on the robot

10 - 19

STYLE010 STYLE019

User Specified

User Specified

20 - 29

STYLE020 STYLE029

User Specified

User Specified

30 - 39

STYLE030 STYLE039

User Specified

User Specified

40 - 49

STYLE040 STYLE049

User Specified

User Specified

50 - 63

STYLE050 STYLE063

User Specified

User Specified - Future expansion

AS OF 1/12/2012 Printed copies are not source controlled

49

CUSW REL1.3

ROBOT INTERFERENCE ZONES Zone Identification Summary/Definitions: Station / Work Area based zones. Zones 1, 2& 3: Station Zones are defined as the area where two or more robots are executing work on or exchanging (transferring) a work piece at a physical station. Examples of stations are turntables, work fixtures, holding bucks and transfers or shuttles. Work Area Zones are defined as the area where two or more robots are executing work on or exchanging (transferring) a work piece without the use of a physical station. Examples of this would be robot to robot hand off by the use of Geo-fector EOAT (End Of Arm Tooling). Station and Work Area Zones are applied using an non-alternating pattern. For example a robot would pick-up a part in Zone 1 then transfer it to Zone 2. The next robot would pick-up the part from Zone 1 then transfers it to Zone 2. This non-alternating pattern would continue with Zone 3 only being required for a robot that needs three Station or Work Area zones.

Transition Zones/Hand-off zones Zones 4 & 5: Transition Zones are when two or more robots, working side by side, are needed to move (transition) from one process area to another process area when a physical interference between the robots is present during the transition. For example welding robots moving from a geo weld position to a re-spot weld position would require some Transition zone protection. Hand-off Zones are used for robot to robot hand-off. Hand-off is when one robot loads the work piece from it EOAT directly onto the other robot‟s EOAT without the use of a station. Hand-off Zones are applied using an non-alternating pattern. For example a robot would pick-up a part in Zone 4 then transfers it to Zone 5. The next robot would pick-up the part from Zone 4 then transfers it to Zone 5 etc.

Process Interference Zones / Duty Zones Zones 6 thru 8: Process Interference Zones are defined as the zones around the work piece that the robots application is working around. For example two or more robots might need to cross each others path in order to complete its process on the work piece. In this case these Process Zones would be used to allow the robots to safely “chase” each other around the work piece. Duty Zones are defined as other Duties that the process or application requires but are in excess of the previous zone definitions. For example, gantry robots having a part transfer at a higher elevation then Zones 1-3 could use these zones like a Work Area Zone. Examples: Interference Zone Example 1: This example shows Zone 1 and 2 as Station Zones. Zones 4 & 5 are Transition Zones and Zones 6 – 8 as Process Interference Zones. Interference Zone Example 2: This example shows Zone 1 and 2 as Work Area Zones. Zone 4 is a hand-off Zone and Zones 6 & 7 are Process Interference Zones

AS OF 1/12/2012 Printed copies are not source controlled

50

CUSW REL1.3

Interference Zone Example 1

AS OF 1/12/2012 Printed copies are not source controlled

51

CUSW REL1.3

Interference Zone Example 2

AS OF 1/12/2012 Printed copies are not source controlled

52

CUSW REL1.3

Interference Zone Example 3

The definitions described and show above, are to be followed as described and are not subject to interpretation. If the above definitions can not be applied to a specific application then approval from a Chrysler Robotics Engineer or Launch Technician will be required to redefine how Interference Zones are to be used. Reference Pictures Only See Standard Robot Logic Reference for Details.

AS OF 1/12/2012 Printed copies are not source controlled

53

CUSW REL1.3

PLC / ROBOT TIMING DIAGRAMS New Cycle Start Robot Inputs *Hold Resume

Production Cycle (2)

Fault Reset Style1-Style64 Option1-Option4

(3)

Prod Start

(3)

Robot Outputs RobotInAuto RobotFaulted-ProcessFault Robot Ready Production Cycle

ActiveStyle1-ActiveStyle64 Prg Paused Prg Running In Cycle Option1Active-Option4Active RobotAtHome

1) Robot is in a starting mode of faulted inbetween cycle 2) Fault Reset can be dropped after seeing Robot Ready go high 3) Style and option bits need to be set before Prod Start is set, Prod Start can be dropped when Prg Running goes high

AS OF 1/12/2012 Printed copies are not source controlled

54

CUSW REL1.3

Stop and Resume from Fault Robot Inputs *Hold

Style1-Style64 Option1-Option4

Production Cycle

Fault Reset

(5)

Production Cycle

Resume

Prod Start

Robot Outputs RobotInAuto RobotFaulted-ProcessFault (4) Robot Ready

Prg Running

Production Cycle

Prg Paused

Production Cycle

ActiveStyle1-ActiveStyle64

In Cycle Option1Active-Option4Active RobotAtHome

4) Fault occurs and robot sets RobotFaulted and/or Process Fault 5) Resume signal does not require Style Number or Option Bits

AS OF 1/12/2012 Printed copies are not source controlled

55

CUSW REL1.3

Stop and Resume from Hold Robot Inputs (6)

*Hold

Style1-Style64 Option1-Option4

Production Cycle

Fault Reset

Production Cycle

Resume

Prod Start

Robot Outputs RobotInAuto RobotFaulted-ProcessFault Robot Ready

Prg Running

Production Cycle

Prg Paused

Production Cycle

ActiveStyle1-ActiveStyle64

In Cycle Option1Active-Option4Active RobotAtHome

6) When *Hold signal is lost, robot pauses program without faults

AS OF 1/12/2012 Printed copies are not source controlled

56

CUSW REL1.3

REGISTER USAGE Register names shall be a maximum of 16 characters in length and the name shall reflect the purpose of the register or counter.

NUMERICAL REGISTER USAGE Numerical Registers are used for storage of Real or Integer values. The table below shows the registers that are reserved.

Table 2. Numerical Registers

Register Number 1

Register Comment Current Tool ID

Current Tool ID

2

Desired Tool ID

Desired Tool ID

3

Devnet Status

DeviceNet Device Status Check Result

4

DevnetConnRetry

DeviceNet Connection Retries

5

Current Home Pos

Home Position to Return to During Service Macro

6

CurrentFixtureID

Current Fixture ID

7

DesiredFixtureID

Desired Fixture ID

8

Line Number

Line Number

9

Register Description

Preset Value

3

Spare

10

SrvGunReserved

11

SrvGunReserved

12

SrvGunReserved

13

SrvGunReserved

14

CompletedBurnIns

Completed Number Burn Ins

15

RequiredBurnIns

Required Number Burn Ins - set by user

16

ATISequenceStep

Current Step of ATI Sequence

17

ATIRecovery

ATI Recovery Method

18

Reserved for ServoGun Tip Wear and Autotuning

3

Spare

19

Gun1BurnInSched

Gun 1 Weld Schedule for Burn In

20

Gun2BurnInSched

Gun 2 Weld Schedule for Burn In

21

Gun1 Spot Count

Gun 1 Spot Weld Count

22

Gun1 Tip Dress

Gun 1 Tip Dress

23

Gun2 Spot Count

Gun 2 Spot Weld Count

24

Gun2 Tip Dress

Gun 2 Tip Dress

25

TipWR Cycle CNT

Tip Wear Cycle Count

26

TipWR Cycle MAX

Tip Wear Max Cycles

27-39

Spare

40

NumWeldRetries

Number of Weld Retries

41

ColGuardDefault

Sensitivity Default Register for Collision Guard

100

42

ColGuardSensitiv

Increased Sensitivity Register for Collision Guard

150

43-100

1

Spare

101

ToolModelNum

102

1sRobot/StatNum

103

10sRobot/StatNum

104-129

Temporary Storage of Tool Model Number Temporary Storage of 1's Digit of Robot/Station Number Temporary Storage of 10's Digit of Robot/Station Number Spare

130

ISRA Mode

Vision Mode

131

ISRA Type

Vision Vehicle Type

132

ISRA Subtype

Vision Vehicle Sub

133

ISRA Color

Vision Vehicle Color

134

ISRA PR

Vision Ofset Index

135

ISRA Error

Vision Error

136

ISRA Temp

Vision Temp

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CUSW REL1.3

Register Number 137

Register Comment

Register Description

ISRA Set Nominal

ISRA Set Nominal

138

ISRA Vis Pos X

ISRA Vis Pos X

139

ISRA Vis Pos Ext

ISRA Vis Pos Ext

140

Rack Position

Rack Position

ISRA Menu ANS

ISRA Menu ANS

145

Scratch1

Scratch1

146

Scratch2

Scratch2

147

Scratch3

Scratch3

149

Part Rapid X

Part Rapid X

150

Part Delta X(mm)

Part Delta X(mm)

151

0th Part X

0th Part X

152

Calc'd Part X

Calc'd Part X

153

Calc'd Part No

Calc'd Part No

154

Search 1 Part X POS

Search 1 Part X POS

155

Search 2 Part X POS

Search 2 Part X POS

156

Search X POS DIF

Search X POS DIF

157

Found Part X

Found Part X

158

Found Part No

Found Part No

159

Part No DIF

160

Part No DIF ForcChkBadMeas

161

ForcChkFailed

162

ForcChk1ShakFail

163

ForcChk2ShakFail

164

ForcChkFShakFail

165

ForcChkPartsRack

Preset Value

141 142 143 144

148

There are a total of 200 numerical registers. The user is free to use any other numerical register. The following is an example of using a numerical register in a teach pendant program. 10: R[1] = 34 ; 11: GO[3] = R[1] ; => Meaning Robot Group Output GO[3] = 34 value

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CUSW REL1.3

POSITION REGISTER USAGE The table below shows the position register list to be used on the WD project. Moving to these positions is handled using the appropriate macro listed in the macro section of this document.

Table 3. Position Registers Position Register Number Position Register Comment 1 Home1

Position Register Description Home1

2

Home2

Home2

3

PouncePosition

Pounce Position

4

M/HWaitPosition

M/H Wait for Dropoff Position

5

ServicePosition

Service Position

6

PurgePositionG1

Purge PositionG1

7

PurgePositionG2

Purge PositionG2

8

Spare

9

Spare

10

Spare

11

Spare

12

Spare

13

Spare

14

Spare

15

Spare

16

Spare

17

Spare

18

Spare

19

Spare

20 21 22 23

ReservedServoGun

Reserved for Servo Gun Autotuning and Tip Wear Operations

ReservedSpotTeach

28

Reserved for Servo Gun Spare

29

Spare

30

Spare

24 25 26 27

31

Pick 1 Position

PickUp Position #1

32

Drop 1 Position

DropOff Position #1

33

Pick 2 Position

PickUp Position #2

34

Drop 2 Position

DropOff Position #2

35

Pick 3 Position

PickUp Position #3

36

Drop 3 Position

DropOff Position #3

37

Pick 4 Position

PickUp Position #4

38

Drop 4 Position

DropOff Position #4

39

Spare

40

Base Frame

Base Frame

41

PF Low Lt Frame

PF Low Lt Frame

42

PF Low Rt Frame

PF Low Rt Frame

43

PF Up Lt Frame

PF Up Lt Frame

44

PF Up Rt Frame

PF Up Rt Frame

45

?? Low Lt Frame

?? Low Lt Frame

46

?? Low Rt Frame

?? Low Rt Frame

47

?? Up Lt Frame

?? Up Lt Frame

48

?? Up Rt Frame

?? Up Rt Frame

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CUSW REL1.3

Position Register Number Position Register Comment 49 Current Position 50 Offs Base Frame 51

Above Pick

52

Position Register Description Current Position Offs Base Frame Above Pick Spare

53

Spare

54

ISRA Vis Pos

ISRA Vis Pos

55

PF Nom Vis Pos

PF Nom Vis Pos

56

?? Nom Vis Pos

?? Nom Vis Pos

57

Rack Nom Vis Pos

Rack Nom Vis Pos

58

ISRA CAM1 CALPOS

ISRA CAM1 CALPOS

59

ISRA CAM2 CALPOS

ISRA CAM2 CALPOS

60 - 89

Spares

90

TCP Target Position

98

Payload ID Position

Starting Position to Start Payload ID

99

ZERO Position

Robot Zero Mastering Position

101

Nest 1 Drop

Spare Position where the tool changer decouples tool 1.

102

Nest 2 Drop

Position where the tool changer decouples tool 2.

103

Nest 3 Drop

Position where the tool changer decouples tool 3.

104

Nest 4 Drop

Position where the tool changer decouples tool 4.

100

105

Spare

106

Nest 1 Pick

Position where the tool changer couples tool 1.

107

Nest 2 Pick

Position where the tool changer couples tool 2.

108

Nest 3 Pick

Position where the tool changer couples tool 3.

109

Nest 4 Pick

Position where the tool changer couples tool 4.

110

Spare

111

Tool Offset 1

Offset used for approach and retreat positions of the robot during the drop sequence.

112

Tool Offset 2

Offset used for approach and retreat positions of the robot during the drop sequence.

113

Tool Offset 3

Offset used for approach and retreat positions of the robot during the drop sequence.

114

Tool Offset 4

Offset used for approach and retreat positions of the robot during the drop sequence.

115

Tool Offset 5

Offset used for approach and retreat positions of the robot during the drop sequence.

116

Tool Offset 6

Offset used for approach and retreat positions of the robot during the drop sequence.

117

Tool Offset 7

Offset used for approach and retreat positions of the robot during the drop sequence.

118

Tool Offset 8

Offset used for approach and retreat positions of the robot during the drop sequence.

119-200

Spares

Note 1: The robot must be able to move between the different Home positions in a single move without causing damage to the robot, dressout, or tooling. Note 2: Only use multiple home positions when performing a Change-out robot program (tool changer application). If no tool change application, the preferred method is only one home position, unless if a cycle time issue comes up.

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USER ALARMS User Alarms are used to post an alarm and fault the robot from within a teach pendant program or macro. The table below shows the user alarms that are used for the PF project.

Table 4. User Alarms User Alarm Number 1

User Alarm Comment ToolNotPresent

No tool present

2

Invalid Tool Requested

Invalid tool requested for pick

3

Unexpected Tool Present

Unexpected tool present for drop

4

Tool Nest not Empty

Tool nest is not empty, can not drop tool

5

Tool Nest is Empty

No tool in nest, can not pick tool

6

DNetPower Not On

Apply DNet power

7

Aux Power Not On

Apply aux power

8

ReadyToLock1 Not On

Tool not positioned properly

9

ReadyToLock2 Not On

Tool not positioned properly

10

ToolStndIntlk1 Not On

TSI limit switch fault

11

ToolStndIntlk2 Not On

TSI limit switch fault

12

RTL Sensor State Mismatch

RTL sensor states don't match

13

TSIV Sensor State Mismatch

TSIV sensor states don't match

14

Latch Overload/Short Circuit

Short circuit or overload on latch solenoid output

15

Unlatch Overload/ShortCircuit

Short circuit or overload on unlatch solenoid output

16

Spare Overload/Short Circuit

Short circuit or overload on spare solenoid output

17

RTLV / RTL Mismatch

Mismatch condition between RTLV and RTL inputs

18

TSRV / TSIV Mismatch

Mismatch condition between TSIV and TSRV inputs

19

UnsafeUnlatch

Unlatch command received resulting in an unsafe tool release and therefore was not processed.

20

LckUnlckSensFlt-Both High

Locked and Unlock inputs high at same time

21

LatchNotComplt-Latch Timeout

Timeout on locked input after latch command

22

UnltchNtComplt-UnlatchTimeout

Timeout on unlocked input after unlatch command

23

TSIVFault-Switch Failed High

Failure of TSIV limit switch(es) in high position

24

RTLFault-Switch Failed High

Failure of RTL sensor(s) in high position

25

CommError-Master to Tool

Communication error between master and tool modules

26

LckOrUnlckSensIncorrectState

Lock or Unlock Sensor in Incorrect State - Possible Failed Sensor

27 - 79

User Alarm Description

Spare

80

ISRA: Reset Errors Timeout

ISRA: Reset Errors Timeout

81

ISRA: Change Auto/Ready Prep

ISRA: Change Auto/Ready Prep

82

ISRA: Change Auto Handshake

ISRA: Change Auto Handshake

83

ISRA: Ready Prep Timeout

ISRA: Ready Prep Timeout

84

ISRA: Meas Data OK Timeout

ISRA: Meas Data OK Timeout

85

ISRA: Result Transfer ON

ISRA: Result Transfer ON

86

ISRA: Result Transfer OFF

ISRA: Result Transfer OFF

87

ISRA: Meas Still Running

ISRA: Meas Still Running

88

ISRA: Wrong Op Mode Entered

ISRA: Wrong Op Mode Entered

90

ISRA: Err Setting Meas Data

ISRA: Err Setting Meas Data

91

ISRA: Err Starting Meas

ISRA: Err Starting Meas

92

ISRA: Features/Tol Error

ISRA: Features/Tol Error

93

ISRA: Measurement Error

ISRA: Measurement Error

89

94 95 ISRA: Rack NOT OK ISRA: Rack NOT OK There are a total of 50 user alarms. The user is free to use any other user alarm. The following is an example of using a user alarm in a teach pendant program. 10: UALM[1] ; 11: UALM[4] ;

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CUSW REL1.3

REFERENCE POSITION USAGE Reference Positions are global positions that can set an output automatically when the robot encoder values indicate that the robot is at the position. This automatic checking is done where the robot is jogged to a position or moved via a macro or program. The table below shows the reference positions to be used on the PF project.

Table 5. Reference Positions Reference Position Number 1

Position Name Home1

At Position Digital Output 27

2

Home2

User Specified

3 - 10

Spare

User Specified

11

RobotAtUserPos1

66

12

RobotAtUserPos2

67

13

RobotAtUserPos3

68

14

RobotAtUserPos4

69

15

RobotAtUserPos5

70

23

UnCouple Tool Position 1

646

24

UnCouple Tool Position 2

647

25

UnCouple Tool Position 3

648

26

UnCouple Tool Position 4

649

27

UnCouple Tool Position 5

650

28

UnCouple Tool Position 6

651

29

UnCouple Tool Position 7

652

30

UnCouple Tool Position 8

653

Note 1: The robot must be able to move between the different Home positions in a single move without causing damage to the robot, dressout, or tooling. Note 2: Only use multiple home positions when performing a Change-out robot program (tool changer application). If no tool change application, the preferred method is only one home position, unless if a cycle time issue comes up. Note 3: Housekeeping macros (HOME_IO) are run when the robot is in range of a reference position set as a valid home position. Reference Position #1 must be set as a valid home position to execute HOME_IO after normal program execution. HOME_IO execution follows normal program execution when a robot is moved from a non home position to a valid home position.

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CUSW REL1.3

INTERCONNECTS The I/O Interconnect feature allows the robot to output the states of digital inputs to notify external devices of the state of those inputs. The interconnect tables displays the inputs that are mapped to outputs. For example, per the configuration in the table below if DI[95] was to turn on, the robot would then turn on DO[416]. If DI[95] then turns off, DO[416] also turns off. I/O is interconnected based on the configuration of the robot. For example, a material handling robot would have Input 513 interconnected to Output 77. It would not have Input 204 interconnected to Output 102 because these I/O points are used for spot welding robots. The table below shows the interconnects that are used for the PF project.

Table 6. Interconnects

INTERCONNECTS Table # Application Type Input 3 7 39 40 41 42 43 44 45 46 47 48 49 50 55 56 57

Reserved Reserved MH MH MH MH MH MH MH MH MH MH MH MH Tool Changing Tool Changing Tool Changing

DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO

DI DI DI625 DI626 DI513 DI514 DI515 DI516 DI529 DI530 DI531 DI532 DI545 DI546 DI664 DI665 DI666

Description

Output

Description

Air OK Air Aceptable Range Part1Present Part2Present Part3Present Part4Present Part5Present Part6Present Part7Present Part8Present Part9Present Part10Present ToolIDSwtch1Bit1 ToolIDSwtch1Bit2 ToolIDSwtch1Bit4

DO DO DO91 DO92 DO77 DO78 DO79 DO80 DO81 DO82 DO83 DO84 DO85 DO86 DO116 DO117 DO118

AirOK AirPressAcptRng RobotPartPres1 RobotPartPres2 RobotPartPres3 RobotPartPres4 RobotPartPres5 RobotPartPres6 RobotPartPres7 RobotPartPres8 RobotPartPres9 RobotPartPres10 ToolIDOnWrist1 ToolIDOnWrist2 ToolIDOnWrist4

INTERCONNECTS Table # 13 14

Type Input Spot Welding Spot Welding

SI-DO SI-DO

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SI12 SI13

Description

Output

Description

OVERTEMP_SWG1 OVERTEMP_SWG2

DO909 DO910

XFORMTEMPOk1 XFORMTEMPOk2

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CUSW REL1.3

MACROS Macro programs can be run standalone, but are intended to be used as subroutines which are called from the main style program. Defining a program as a macro program is done by setting the program type to “Macro” in the program header. When these programs are called from a main style program, the program pointer jumps to the subroutine. Similarly, when the subroutine is complete, the program pointer jumps back to the next line in the main style program. Macro programs can be set to either prohibit or allow robot motion statements. When motion statements are prohibited, the macro program can be manually executed while a robot fault is active. Therefore, it is recommended that macro programs that only execute I/O signals be set to prohibit motion statements (i.e. open/close gripper macro programs). Prohibiting motion statements in a macro program is done by setting all available motion groups to “*” in the program header. Allowing motion statements in a macro program is done by setting the appropriate motion groups to “1”. The user is free to place additional macros into the macro table provided they do not take up a position reserved by the macro table listed below. FANUC Spottool+ standard macros such as tip wear compensation are not called out in the macro table. These macros are automatically loaded on the robot at time of software load.

Table 7. Macros Macro Table Position Macros 1

Macro Name (8 Char. Max)

Macro Comment (16 Char. Max)

Macro Description

HOME_IO

Setup Outputs

Handles I/O for start of next cycle (housekeeping)

APP_IO

SetApplicationIO

Setup all application specific inputs and outputs

ATI_CHCK

Check ATI Errors

Handles ATI errors experienced during the tool pick and tool drop processes

CHK_TOOL

Check Tool

Checks for the correct tool on the wrist

ENTRZON1

Enter Zone 1

Handles IO for zone entering

ENTRZON2

Enter Zone 2

Handles IO for zone entering

ENTRZON3

Enter Zone 3

Handles IO for zone entering

ENTRZON4

Enter Zone 4

Handles IO for zone entering

ENTRZON5

Enter Zone 5

Handles IO for zone entering

ENTRZON6

Enter Zone 6

Handles IO for zone entering

ENTRZON7

Enter Zone 7

Handles IO for zone entering

ENTRZON8

Enter Zone 8

Handles IO for zone entering

ENTRZON9

Enter Zone 9

Handles IO for zone entering

MOV_HOME

Move to Home

Executes motion to move the robot home from the current position

MVHMPNCE

MoveHomeFromPnce

Executes motion to move the robot home from the pounce position

NST1DROP

Drop Tool Nest 1

Executes motion and/or macro calls required to drop tool 1 in nest 1

NST2DROP

Drop Tool Nest 2

Executes motion and/or macro calls required to drop tool 2 in nest 2

NST3DROP

Drop Tool Nest 3

Executes motion and/or macro calls required to drop tool 3 in nest 3

NST4DROP

Drop Tool Nest 4

Executes motion and/or macro calls required to drop tool 4 in nest 4

MF 1

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CUSW REL1.3

Macro Table Position

Macro Name (8 Char. Max) NST1PICK

Macro Comment (16 Char. Max) Pick Tool Nest 1

NST2PICK

Pick Tool Nest 2

Executes motion and/or macro calls required to pick tool 2 from nest 2

NST3PICK

Pick Tool Nest 3

Executes motion and/or macro calls required to pick tool 3 from nest 3

NST4PICK

Pick Tool Nest 4

Executes motion and/or macro calls required to pick tool 4 from nest 4

PED_DISP

Ped Dispense

Executes motion and/or macro calls required to perform dispensing with a pedestal mounted gun

PED_SPOT

Ped Spot Weld

Executes motion and/or macro calls required to perform spot welding with a pedestal mounted weld gun

PED_STUD

Ped Stud Weld

Executes motion and/or macro calls required to perform stud welding with a pedestal mounted gun

PREPDROP

Tool Drop Prep

Executes motion and/or macro calls required to prepare to drop the tool on the wrist in its nest

PREPPICK

Tool Pick Prep

Executes motion and/or macro calls required to prepare to pick a tool from its nest

PRGPDGN1

Purge Ped Gun 1

Executes motion and/or macro calls required to perform a purge on pedestal mounted dispense gun 1

RST_STPR

Reset Stepper

Handles IO for resetting the spot weld stepper motor

TPBURNIN

Tip Burn In

Executes motion and/or macro calls required to perform a tip burn in on a servo weld gun

TPCHNGPD

TipChangePedGun

Executes motion and/or macro calls required to perform a tip change on a pedestal mounted weld gun

TPDRSPD

TipDressPedGun

Executes motion and/or macro calls required to perform a tip dress with a pedestal mount weld gun

TPDRSGN1

DressCarriedGun1

Executes motion and/or macro calls required to perform a tip dress on carried weld gun 1

TPDRSGN2

DressCarriedGun2

Executes motion and/or macro calls required to perform a tip dress on carried weld gun 2

Macro Description Executes motion and/or macro calls required to pick tool 1 from nest 1

10 - 11

Reserved for SpotTool+

18

Reserved for SpotTool+

109 - 120

Reserved for SpotTool+

130 - 140

Reserved for SpotTool+

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CUSW REL1.3

FLOW CHART EXAMPLES Contained in the following pages are flow charts of the processes required for the PF program. The information contained in each section is for REFERENCE ONLY.

Flow Chart Legend Process: Logic statement

Data: Data/Input from an external device is required to process this step‟s logic

Decision: Logic decision

Move: Servo movement called in logic

Connector: Off Page

Connector: On Page

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CUSW REL1.3

Material Handling Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1] Reset Collision Guard Sensitivity to Default R[41]

Tool Changer Applications Only

No Tool Changer

Set Desired Tool ID R[2] Check Tool (Macro)

Set MH Gripper (if necessary) (Macro)

Set additional gripper states (if necessary) (Macro)

A

Move to Pounce

Wait for go to Pickup 1 DI[49]

Set at Pounce DO[25] Reset Clear of Pickup 1 DO[49] Reset DO[89] Reset DO[94]

Reset Clear to Transfer DO[31]

Verify Part not Present (Macro)

Zone Check (if necessary) (Macro)

Open the Gripper and Verify Open (Macro)

Go to Work or Return Home From Pounce?

Move Over Pickup 1

Return Home DI[25]

Move Home from Pounce (call Macro)

Verify Tool is Correct (Macro)

Verify Part not Present (Macro)

Go To Work DI[31] End Set Robot at Work DO[18] Reset Robot at Pounce DO[25]

B

A

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CUSW REL1.3

Material Handling (cont’d) B

Open the Gripper and Verify Open (Macro)

Set Collision Guard Sensitivity R[42]

Move to Pickup 1

Check for Part Present (Macro)

Note: Material Handling functions may require process recovery. Refer to the MH process recovery section.

Set Reposition Tooling GO[2]

Wait for Tooling Repositioned GI[5]

Close the gripper and verify closed (Macro)

Note: Collision Guard sensitivity increased prior to moving into tooling to help prevent damage if a collision occurs

Note: Set reposition tooling handshake may be required either before or after gripper is closed

Note: Receiving robot or fixture will always set the Reposition Tooling bit to the delivering robot or fixture

Note: Reposition Tooling bits only required when Robot to Robot/Fixture handshaking is needed

Set At Pickup 1 DO[50] Select Robot Payload with Part

Note: Validate open before moving

Wait for Tooling Repositioned GI[5]

Reset Reposition Tooling GO[2]

Move Clear of Fixture Part Presence

Wait for Exit Pickup 1 DI[50]

Reset Collision Guard Sensitivity to Default R[41]

Note: This robot movement must be of “FINE” type

Note: Lessons learned, PLC is looking for a part in the robot gripper and has not been dropped

Check for Part Present (if necessary) (Macro)

C

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CUSW REL1.3

Material Handling (cont’d)

C

Reset at Pickup 1 DO[50]

Move Clear of Pickup 1

Set Clear of Pickup 1 DO[49] Set Clear to Transfer DO[31] Set Clear of Interference Zone (if necessary) DO[33]

Move

Process Applications (as required) Dispense Inspection Spot Weld Stud Weld Wait for go to Dropoff 1 DI[51]

Zone Check (if necessary) (Macro)

Reset Clear of Dropoff 1 DO[51] Reset Clear to Transfer DO[31]

Move Over Dropoff 1

Verify Tool is Correct (Macro)

Set Collision Guard Sensitivity R[42]

Move to Dropoff 1

Set at Dropoff 1 DO[52]

D

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CUSW REL1.3

Material Handling (cont’d)

D

Note: Receiving robot or fixture will always set the Reposition Tooling bit to the delivering robot or fixture

Wait for Reposition Tooling GI[5]

Open the Gripper (Macro) Select Payload without Part(s), Tool Frame and User Frame

Note: Reposition Tooling bits only required when Robot to Robot/Fixture handshaking is needed

Set Tooling Repositioned GO[2]

Note: Material Handling functions may require process recovery. Refer to the MH process recovery section.

Note: Assumes robot drops part to fixture

Move Clear of Robot Part Present

Note: This robot movement must be of “FINE” type.

Verify Parts Not Present (Macro)

Wait for Exit Dropoff 1 DI[52] (if necessary)

Reset Collision Guard Sensitivity to Default R[41] Reset at Dropoff 1 DO[52] Reset Tooling Repositioned GO[2]

Move Clear of Dropoff 1

Set Clear of Dropoff 1 DO[51] Set Clear of Interference Zone (if necessary) DO[33]

E

Move Clear of Transfer Set Work Complete DO[19] Set Clear to Transfer DO[31] Reset Robot at Work DO[18]

Wait for Work Complete Ack. DI[32]

Move Home (Macro)

Reset Work Complete DO[19]

E

End

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CUSW REL1.3

Material Handling (cont’d) Abort Pick/Abort Override Example (if required) From Standard Material Handling Process

Note: Abort outputs are automatically set when the user selects a designated recovery option during standard material handling fault recovery (DO[89,94]). The user must manually reset these outputs when the recovery process is complete.

MH Function Macro (Ex: Check Part Present)

Abort Pick or Abort Over Ride Requested? DO[89,94]

No Continue Standard Material Handling Process

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Yes

User Specified Macro (Ex: Abort Pick) Jump to Program Label (Ex: End Program)

CUSW REL1.3

Dispense Start

A

Set Robot Payload, Tool Frame, and User Frame

Reset Dispense Style GO[31]

Setup Application Specific I/O (Macro) Note: Collision Guard sensitivity increased prior to moving into tooling to help prevent damage if a collision occurs

Acknowledge Style GO[1] Reset Collision Guard Sensitivity to Default R[41] Reset Clear to Transfer DO[31]

Set Collision Guard Sensitivity R[42]

Move To Seal Start and Turn on Gun

Move to Pounce

Note: The Nordson controller requires approx 500ms between the final gun off command and setting dispense complete. Therefore a move clear of part is performed between these commands to allow this time to elapse.

Set at Pounce DO[25]

Go to Work or Return Home From Pounce?

Reset Dispense Style Strobe DO[394]

Return Home DI[25]

Move To Seal End and Turn off Gun

Move Clear of Part Move Home from Pounce (Macro)

Go To Work DI[31]

Reset Collision Guard Sensitivity R[41]

Set Robot at Work DO[18] Reset Robot at Pounce DO[25]

Move Along Path

Set Dispense Complete DO[401]

End

Zone Check (if necessary) (Macro)

Wait for Dispense Vol. OK

Pre-processing for Dispense Equipment

Reset Dispense Complete DO[401] Reset Dispense Robot in Process DO[393]

Wait for Dispenser Ready DI[385]

Set Dispense Robot in Process DO[393] Wait 100ms Set Dispense Style GO[31] Wait 100ms Set Dispense Style Strobe DO[394]

Post-processing for Dispense Equipment

Move Home (Macro)

Note: The Nordson controller requires 100ms delay time between setting robot in process, dispense style, and dispense style strobe. Wait statements are used here to allow the Nordson to see the delay.

Set Work Complete DO[19] Set Clear to Transfer DO[31] Set Clear of Zone DO[33]

Wait for Dispense In Process DI[386]

Wait for Work Complete Ack. DI[32]

A

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End

72

Reset Work Complete DO[19]

CUSW REL1.3

Spot Welding Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1] Reset Clear to Transfer DO[31]

Move to Pounce

Set at Pounce DO[25]

Go to Work or Return Home From Pounce?

Return Home DI[25]

Move Home from Pounce (Macro)

Go To Work DI[31] End Set Robot at Work DO[18] Reset Robot at Pounce DO[25]

Zone Check (if necessary) (Macro)

Move To Weld 1

Select Schedule, Weld 1

Move To Weld 2

Select Schedule, Weld 2

Move Clear of Clamps

A

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Spot Welding (cont’d)

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CUSW REL1.3

Stud Welding Start

A

Set Robot Payload, Tool Frame, and User Frame

Set Clear to Unclamp Early DO[65]

Setup Application Specific I/O (Macro) Acknowledge Style GO[1]

Move Home (Macro)

Reset Clear to Transfer DO[31]

Set Work Complete DO[19] Move to Pounce

Set Clear to Transfer DO[31] Set Clear of Zone DO[33]

Set at Pounce DO[25]

Go to Work or Return Home From Pounce?

Return Home DI[25]

Wait for Work Complete Ack. DI[32] Move Home from Pounce (Macro)

Reset Work Complete DO[19]

Go To Work DI[31] End

End

Set Robot at Work DO[18] Reset Robot at Pounce DO[25]

Zone Check (if necessary) (Macro)

Move To Weld 1

Select Schedule, Weld 1

Move To Weld 2

Select Schedule, Weld 2

Move Clear of Clamps

A

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CUSW REL1.3

Tip Change (Style #3) Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1]

Move Dress Approach (if necessary)

Note: A tip dress is performed prior to cap change to allow operator to verify tip dresser is properly dressing caps.

Do Tip Dress Gun 1 – Schedule 0 (Macro) DELAY for TipDress Complete (wait 1.0 sec)

Note: Tip Dress Macros use an argument call for the burn in schedule. Schedule 0 skips the burn in.

Reset Tip Dress Complete DO[29] Move to Tip Change Position

Pulse W 1 W ater Off DO[587]

Note: 4.0 sec puls required to allow the watersaver to turn OFF and Blead down.

W ait W 1OKToW eld DI[785]=OFF AND W 1ValveClosed DI[786]=ON

Set Robot at Service DO[26]

Reset Robot at Service DO[26]

Set Ready for Tip Change DO[30]

Reset Ready for Tip Change DO[30] Reset Stepper (Macro)

W ait for Service Complete DI[26]

Seat Caps Gun 1 (Macro) Do Tip W ear Compensation Gun 1 (Macro)

Note: Tip wear compensation to be performed without measurement error checking.

Move Dress Approach (if necessary)

Pulse W 1 Reset W ater Saver DO[586] W ait W 1OKtoW eld DI[785]=ON

Note: Tip dress macros perform burn in and wear compensation after dress. Refer to macros for details.

Do Tip Dress Gun 1 – (Macro)

Move Home (Macro)

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End

CUSW REL1.3

Purge (Style #4) Start

Setup Application Specific I/O (Macro) Acknowledge Style GO[1] Set Ext Purge 1 in Progress DO[97] Pre-processing for Dispense Equipment Set Dispense 1 Purge DO[416] Wait „X‟ Seconds Reset Dispense 1 Purge DO[416] Post-processing for Dispense Equipment

Note: Home IO may need to be manually initiated if the style program does not have any robot motion.

Reset Ext Purge 1 in Progress DO[97] Home IO (if necessary) (Macro)

End

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77

CUSW REL1.3

Tip Burn In (Style #5) Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1]

Move to Service Position (if necessary)

Tip Burn In (Macro)

Move Home (Macro) (if necessary)

Home IO (Macro) (if necessary)

End

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78

CUSW REL1.3

Service (Style #6) Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1]

Move to Service Position

Set Robot at Service DO[26]

Wait for Service Complete Req. DI[26]

Reset Robot at Service DO[26]

Move Home (Macro)

End

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79

CUSW REL1.3

Tip Dress Gun 1 (Style #7) Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1]

Approach Move (if necessary) Note: Tip Dress Macros use an argument call for the burn in schedule. Schedule 0 skips the burn in.

Tip Dress Gun 1 – (Macro)

Note: Tip dress macros perform burn in and wear compensation after dress. Refer to macros for details.

Move Home (Macro)

End

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80

CUSW REL1.3

Tip Dress Gun 2 (Style #8) Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1]

Approach Move (if necessary) Note: Tip Dress Macros use an argument call for the burn in schedule. Schedule 0 skips the burn in.

Tip Dress Gun 2 – (Macro)

Note: Tip dress macros perform burn in and wear compensation after dress. Refer to macros for details.

Move Home (Macro)

End

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81

CUSW REL1.3

Tool Change (Style #9) Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1]

Set Desired Tool ID GI[41]

Check Tool (Macro)

Move Home (Macro)

End

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CUSW REL1.3

Set Application IO (Macro) Start

Set Application Specific IO

End

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83

CUSW REL1.3

Check ATI Errors (Macro) Start A

Select Current Sequence AR[1] Set ATI Recovery Method R[17]

No

Sequence List AR[1]: A. Ready to Pick/Latch/Unlatch B. Ready to Latch C. Exit Pick/Ready to Drop/Exit Drop D. Ready to Unlatch

ATI Error Present?

Yes End Post User Alarm for ATI Error and Pause Program

R[17]=1

Select Recovery Method R[17]

R[17]=0

Reset Latch Tool DO[632]

Set Clear Errors DO[635]

Reset Unlatch Tool DO[633]

Wait „x‟ seconds for ATI to reset

Set Clear Errors DO[635]

Reset Clear Errors DO[635]

Wait „x‟ seconds for ATI to reset Reset Clear Errors DO[635] A

End

Note: This recovery method will retry the latch or unlatch operation in the pick or drop macro upon exiting.

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84

CUSW REL1.3

Check Tool (Macro) Start

Set Tool ID R[1], Line Number R[8], and Tool ID for PLC GO[3]

Yes

Does Current Tool ID Match Desired Tool ID?

No

End

Is Tool on Wrist? DI[644] R[1]

Yes

No

Pick Preparation and Pick Tool (Macro)

Drop Preparation and Drop Tool (Macro)

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85

CUSW REL1.3

Drop Tool Nest 1 (Macro) Start

Set Robot UTOOL and UFRAME

Set Request to Enter Tool Nest DO[71]

Wait for Clear to Enter Tool Nest DI[81]

Clear ATI Errors DO[635] Reset Clear of Tool Nest DO[72] Reset Request to Enter Tool Nest DO[71]

Set Tool Device Offline (Macro) Note: (if applicable) Tool nest 1 approach and retreat positions are to use the same position as the couple position, PR[6]. This position is then offset by a distance using a tool offset via position register, PR[14].

Move to Tool Nest Perch

ATI General Error DO[645] High?

No

Yes ATI State Check – Sequence 5 (Macro)

Note: Turn Out of Nest off before TSIV switches are made. When the Out of Nest Output is set high, the tool changer globally disables the unlatch command. This output must be turned off to unlatch the tool changer.

Reset Out of Nest DO[637]

Move to Tool Nest

Wait for Tool in Nest 1 DI[73]

ATI State Check – Sequence 6 (Macro)

A

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86

CUSW REL1.3

Drop Tool Nest 1 (cont’d) Note: In the robot ladder logic, PMC the following logic is added: (Even if you ONLY have one tool, you must define a Reference Position (below) in order to UnCouple a tool.) IF DO[646:UnCoupleToolPos1]=ON or DO[647:UnCoupleToolPos2]=ON or DO[648:UnCoupleToolPos3]=ON or DO[649:UnCoupleToolPos4]=ON or DO[650:UnCoupleToolPos5]=ON or DO[651:UnCoupleToolPos6]=ON or DO[652:UnCoupleToolPos7]=ON or DO[653:UnCoupleToolPos8]=ON THEN turn DO[RbtOKtoUnCouple]=ON

ReferncePos[11] ReferncePos[12] ReferncePos[13] ReferncePos[14] ReferncePos[15] ReferncePos[16] ReferncePos[17] ReferncePos[18]

A

Note: You do NOT need to set this DO[654] output in robot TP, this will be handled in robot code. It is FYI for you.

Reset Latch Tool DO[632] Set Unlatch Tool DO[633]

RbtOKtoUnCouple DO[654]

Unlatch DI[633] High?

Code in KAREL to Unlock: IF (DO[637] = OFF) AND (DO[633]+) AND (DO[654]=ON) THEN DO[633]=ON

Yes ATI Unlatched or General Error?

General Error DO[645] ATI State Check – Sequence 7 (Macro)

Tool Unlocked DI[633] Not Tool Locked DI[632] Note: (if applicable) Tool nest 1 approach and retreat positions are to use the same position as the couple position, PR[6]. This position is then offset by a distance using a tool offset via position register, PR[14]. This move must be 1 inch further than complete separation of the tool and be of “FINE” type

No - Timeout

Set Robot Payload without Tool Set Robot UTOOL and UFRAME

Move Clear of Tool in Nest Inputs Note: Check for disengagement of tool changer

Wait for Tool in Nest 1 DI[73]

ATI General Error DO[645] High?

Yes

ATI State Check – Sequence 8 (Macro)

No Wait for Tool in Nest 1 DI[73] Move 4 Inches Above Clear of Tool in Nest

Reset Unlatch Tool DO[633] Set Out of Nest DO[637] Clear ATI Errors DO[635] Set Robot UTOOL and UFRAME

Move Clear of Tool Nest

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End

CUSW REL1.3

Enter Zone 1 (Macro) Start

Reset Clear of Zone 1 DO[33]

W ait for OK to Enter Zone 1 DI[33]

End

Home IO (Macro) Start

Set Housekeeping Outputs

End

Move Home (Macro) Start

Call Get_HOME (Karel Program)

Move Home

NOTE: Get_Home Karel program will copy the position taught in Reference position to PR[Home]

NOTE: Fine Move Required

End

Move Home From Pounce (Macro) Start

Move Home From Pounce

End

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88

CUSW REL1.3

Pick Tool Nest 1 (Macro) Start

Clear ATI Errors DO[635]

Set Robot UTOOL and UFRAME

Set Request to Enter Tool Nest DO[71]

Move to Tool Nest Perch

Wait for Clear to Enter Tool Nest DI[81]

Reset Clear of Tool Nest DO[72] Reset Request to Enter Tool Nest DO[71]

Note: (if applicable) Tool nest 1 approach and retreat positions are to use the same position as the couple position, PR[6]. This position is then offset by a distance using a tool offset via position register, PR[10].

Move to Tool Nest Approach

Reset Out of Nest DO[637]

No User Alarm – Lock or Unlock Sensor Incorrect State

Note: Turn Out of Nest off before TSI switches are made. When the Out of Nest Output is set high, the tool changer globally disables the unlatch command. This output must be turned off to unlatch the tool changer.

Tool Locked and Tool Unlocked Low?

Yes Reset Latch Tool DO[632] Set Unlatch Tool DO[633]

Unlatch DI[633] High?

Yes

No - Timeout

ATI Unlatched or Error Posted?

General Error DO[645] ATI State Check – Sequence 1 (Macro)

Tool Unlocked DI[633] Move to Tool Nest

ATI State Check – Sequence 2 (Macro)

A

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89

CUSW REL1.3

Pick Tool Nest 1 (cont’d)

A

Reset Unlatch Tool DO[633] Set Latch Tool DO[632]

Set Tool Device Online (Macro)

Latch DI[632] High?

Yes

No - Timeout ATI Latched or Error Posted?

General Error DO[645]

Tool Locked DI[632] Not Tool Unlocked DI[633]

ATI State Check – Sequence 3 (Macro)

Set Robot Payload with Tool Set Robot UTOOL and UFRAME

Is Tool ID correct? Note: (if applicable) Tool nest 1 approach and retreat positions are to use the same position as the couple position, PR[6]. This position is then offset by a distance using a tool offset via position register, PR[10].

No User Alarm – Unexpected Tool Present

Yes Move Clear of Tool in Nest Inputs

ATI General Error DO[645] High?

End

Yes ATI State Check – Sequence 4 (Macro)

No

Move Clear of Tool Nest

Set Out Of Nest DO[637]

Set Robot UTOOL and UFRAME

Set Tool Device Online (Macro)

No Move Clear of Tool Nest

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Check Device Online

90

End

Yes

CUSW REL1.3

Process Application Macros (Spot, Dispense, Stud) MH Ped Spot Weld Start

Move To Weld 1

Select Schedule, Weld 1

Move To Weld 2

Select Schedule, Weld 2

Move Clear of Ped Welder

Tip Dress, Tip Change, Burn In, Service or Go To Dropoff?

Tip Change DI[105]

Dropoff 1 DI[51]

Tip Dress Ped Gun – Schedule 0 (Macro) Reset Tip Dress Complete DO[29]

Tip Burn In (Macro)

Tip Dress DI[28]

Tip Change Ped Gun (Macro) End

Tip Dress Ped Gun – Schedule 58 (Macro)

Note: Refer to flow charts for tip change and tip dress macro details

Tip Burn In DI[104]

Note: A tip dress is performed prior to tip change to allow operator to verify tip dresser is properly dressing caps.

Tip Dress Ped Gun – Schedule 62 (Macro)

Service Request DI[27] MH Service with Part – (Macro)

Note: Tip Dress Macros use an argument call for the burn in schedule. Schedule 0 skips the burn in.

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CUSW REL1.3

Process Application Macros (cont’d) MH Ped Dispense Start

A

Pre-processing for Dispense Equipment

Wait for Dispense Vol. OK

Wait for Dispenser Ready DI[385]

Set Dispense Robot in Process DO[393] Wait 100ms Set Dispense Style GO[31] Wait 100ms Set Dispense Style Strobe DO[394]

Reset Dispense Complete DO[401] Reset Dispense Robot in Process DO[393]

Note: The Nordson controller requires 100ms delay time between setting robot in process, dispense style, and dispense style strobe. Wait statements are used here to allow the Nordson to see the delay.

Wait for Dispense In Process DI[386]

Post-processing for Dispense Equipment

Purge Gun 1 DI[95]

Reset Dispense Style GO[31]

Purge or Go To Dropoff?

Dropoff 1 DI[51]

Purge Ped Gun 1 (Macro)

Reset Dispense Style Strobe DO[394] End

Set Collision Guard Sensitivity R[42]

Move To Seal Start and Turn on Gun

Move Along Path

Move To Seal End and Turn off Gun

Move Clear of Nozzle

Reset Collision Guard Sensitivity R[41]

Note: The Nordson controller requires approx 500ms between the final gun off command and setting dispense complete. Therefore a move clear of part is performed between these commands to allow this time to elapse.

Set Dispense Complete DO[401]

A

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CUSW REL1.3

Process Application Macros (cont’d)

MH Ped Stud Weld Start

Move To Weld 1

Select Schedule, Weld 1

Move To Weld 2

Select Schedule, Weld 2

Move Clear of Ped Welder

End

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CUSW REL1.3

Purge Ped Gun (Macro) Start

Set Ext Purge 1 in Progress DO[97] Pre-processing for Dispense Equipment Set Dispense 1 Purge DO[416] Wait „X‟ Seconds Reset Dispense 1 Purge DO[416] Post-processing for Dispense Equipment Reset Ext Purge 1 in Progress DO[97]

End

Reset Stepper (Macro) Start

Set W1 Reset Stepper DO[590]

Wait for Stepper Reset DI[204]

Reset W1 Reset Stepper DO[590]

End

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CUSW REL1.3

Tip Burn In (Macro) Start

Reset Register for Burn Ins Complete R[14]

Do Tip Burn In Weld Schedule 62

Completed # of Burn In‟s Required?

No

Note: Number of required burn in‟s to be set by user via register value 15.

Yes Do Tip Wear Compensation Gun 1 (Macro) Set Tip Burn In Complete DO[104]

Note: Tip wear compensation to be performed without measurement error checking.

End

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CUSW REL1.3

Tip Change Ped Gun (Macro) Start

Pulse W1 Water Off DO[587] Set Robot at Service DO[26] Set Ready for Tip Change DO[30]

Wait for Service Complete DI[26]

Reset Robot at Service DO[26] Reset Ready for Tip Change DO[30] Reset Stepper (Macro) Seat Caps Gun 1 (Macro) Do Tip Wear Compensation Gun 1 (Macro) Pulse W1 Reset Water Saver DO[586]

End

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CUSW REL1.3

Tip Dress Gun 1 (Macro) Start

Setup Gun 1 Burn in Schedule R[19]

No

Tip dress Bypassed R[127]

Yes Set Robot in Tip Dress DO[28]

Move Common Dress Approach Set Turn on Tip Dresser DO[101] Wait for Tip Dress Motor On DI[101]

No

Tip Burn In Required R[19]

Yes

Move To Dresser

Do Tip Burn In Weld Schedule R[19]

Do Tip Dress Weld Schedule 60

Do Tip Wear Compensation Gun 1 (Macro) Move Away from Dress

Note: Tip burn in and wear compensation can be skipped. This is to be used only prior to tip change when burn in and wear compensation is not required after a tip dress. Note: Tip wear compensation to be performed without measurement error checking.

Reset Turn On Tip Dresser DO[101]

Reset Tip Dress Request 1 DO[100] [PR Home – Fine Move] Set Tip Dress Complete DO[29]

Reset Robot in Tip Dress DO[28]

End

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CUSW REL1.3

Tip Dress Gun 2 (Macro) Start

Setup Gun 2 Burn in Schedule R[20]

No

Tip dress Bypassed R[127]

Yes Set Robot in Tip Dress DO[28]

Move Common Dress Approach Set Turn on Tip Dresser DO[101] Wait for Tip Dress Motor On DI[101]

No

Tip Burn In Required R[20]

Yes

Move To Dresser

Do Tip Burn In Weld Schedule R[20]

Do Tip Dress Weld Schedule 61

Do Tip Wear Compensation Gun 2 (Macro) Move Away from Dress

Note: Tip burn in and wear compensation can be skipped. This is to be used only prior to tip change when burn in and wear compensation is not required after a tip dress. Note: Tip wear compensation to be performed without measurement error checking.

Reset Turn On Tip Dresser DO[101]

Reset Tip Dress Request 1 DO[100] [PR Home – Fine Move] Set Tip Dress Complete DO[29]

Reset Robot in Tip Dress DO[28]

End

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CUSW REL1.3

Tip Dress Ped Gun (Macro) Start

Setup Gun 1 Burn in Schedule R[19] Set Robot in Tip Dress DO[28]

Wait for Tip Dress Dump Ext DI[99]

Turn on Tip Dresser DO[101]

Wait for Tip Dress Motor On DI[101]

Do Tip Dress Weld Schedule 60

Reset Turn on Tip Dresser DO[101] Reset Tip Dress Request 1 DO[100] Set Tip Dress Complete DO[29]

Wait for Tip Dress Dump Retracted DI[100]

No

Tip Burn In Required R[19]

Yes Do Tip Burn In Weld Schedule R[19]

Do Tip Wear Compensation Gun 1 (Macro)

Reset Robot in Tip Dress DO[28]

End

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CUSW REL1.3

Tool Drop Preparation (Macro) Start

Select Tool from Tool Number R[16]

Unknown Tool

Tool 1

A

Set Application Error Output

Set Application Error Output

User Alarm – Unexpected Tool Present

User Alarm – Tool Nest Not Empty

Reset App Error Output

Reset App Error Output

Verify Part Not Present (Macro) Set Active MH Tool and Gripper State for Drop (Macro)

Tool Nest 1 Empty?

Yes

Drop Tool Nest 1 (Macro)

No A

Tool 2

Verify Part Not Present (Macro) Set Active MH Tool and Gripper State for Drop (Macro)

Tool Nest 2 Empty?

Yes

Drop Tool Nest 2 (Macro)

No A

Tool 3

Verify Part Not Present (Macro) Set Active MH Tool and Gripper State for Drop (Macro)

Tool Nest 3 Empty?

Yes Drop Tool Nest 3 (Macro)

No A

Tool 4

Verify Part Not Present (Macro) Set Active MH Tool and Gripper State for Drop (Macro)

Tool Nest 4 Empty?

Yes Drop Tool Nest 4 (Macro)

No A

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End

CUSW REL1.3

Tool Pick Preparation (Macro) Start

Select Tool Nest from Pick Tool GI[4] or Style Program

Unknown Tool

Tool 1

A

Set Application Error Output

Set Application Error Output

User Alarm – Invalid Tool Requested

User Alarm – Tool Nest Empty

Reset App Error Output

Reset App Error Output

No

Tool Nest 1 Empty?

Pick Tool Nest 1 (Macro)

Yes A

Tool 2

No

Tool Nest 2 Empty?

Pick Tool Nest 2 (Macro)

Yes A

Tool 3

No

Tool Nest 3 Empty?

Pick Tool Nest 3 (Macro)

Yes A

Tool 4

No

Tool Nest 4 Empty?

Pick Tool Nest 4 (Macro)

Yes A End

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CUSW REL1.3

TEACH PENDANT LOGIC EXAMPLES Contained in the following pages are examples of TP logic of the processes required for the PF program. The information contained in each section is for REFERENCE ONLY.

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CUSW REL1.3

Material Handling 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40: 41: 42: 43: 44: 45: 46: 47: 48: 49: 50: 51: 52: 53:J 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67: 68: 69: 70: 71: 72: 73: 74: 75:

!Material Handling Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ; UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=10 ; ; !Reset Coll Guard Sensitivity ; COL GUARD ADJUST ; ; !****************************** ; !TOOL CHANGE APPLICATION ONLY ; ; !Set Desired Tool ID Register ; R[2:Desired Tool ID]=2 ; ; !MACRO-Check Tool ; CALL CHK_TOOL ; ; !MACRO-Set MH Tool ; Set MH Tool(1) ; !****************************** ; ; !MACRO-Set Additional Gripper ; !States (if necessary) ; !Grip Part(2) ; ; !Move to Pounce ; P[1] 100% CNT100 ; ; !Set At Pounce Position Bit ; DO[25:RbtAtPounce]=ON ; ; !MACRO-Verify Part Not Present ; Check No Part(1) ; ; !MACRO-Open the Gripper ; Release Part(1) ; ; DO[89:PickOverride]=OFF ; DO[94:AbortPickReq]=OFF ; ; !Wait For Go To Work ; !or Return Home From Pounce ; WAIT DI[31:GoToWork]=ON OR DI[25:RetFromPounce]=ON ; ; !Check For Go To Work ; IF DI[31:GoToWork]=ON,JMP LBL[20] ; ; !Return Home From Pounce ; CALL MVHMPNCE ;

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103

; !Jump To Program End ; JMP LBL[1000] ; ; LBL[20:Go To Work] ; ; !Set Robot At Work ; DO[18:RbtAtWork]=ON ; ; !Reset Robot At Pounce ; DO[25:RbtAtPounce]=OFF ; ; !Wait For Go To Pickup 1 ; WAIT DI[49:GoToPickup1]=ON ; ; !Reset Clear Of Pickup 1 ; DO[49:ClrOfPickup1]=OFF ; ; !Reset Clear To Transfer ; DO[31:CleartoTransfer]=OFF ; ; !MACRO-Zone Check ; !(if necessary) ; CALL ENTRZON1 ; ; !Move Over Pickup 1 ; P[2] 1000mm/sec CNT100 ; ; !MACRO-Verify Correct Tool ; !Call TOOL_VER ; ; !MACRO-Verify Part Not Present ; Check No Part(1) ; ; !MACRO-Open the Gripper ; Release Part(1) ; ; !Set Coll Guard Sensitivity ; COL GUARD ADJUST R[42]; ; !Move To Pickup 1 ; P[3] 500mm/sec FINE ; ; !MACRO-Check For Part Present ; Part Present(1) ; ; !Set Reposition Tooling ; !GO[2:ReposTooling]=1 ; ; !Wait for Tooling Repositioned ; !WAIT GI[5:ToolingRepod1]=1 ; ; !MACRO-Close The Gripper ; Grip Part(1) ; ; !Set At Pickup 1 ; DO[50:AtPickup1]=ON ; ; !Select Payload With Parts ; PAYLOAD[3] ; ; !Wait for Tooling Repositioned ; !WAIT GI[5:ToolingRepod1]=1 ; ; !Reset Reposition Tooling ; !GO[2:ReposTooling]=0 ; ; !Move Clear Fixt Part Presence ; P[4] 1000mm/sec FINE ; ; !Wait For Exit Pickup 1 ; WAIT DI[50:ExitPickup1]=ON ; ; !Reset Coll Guard Sensitivity ; COL GUARD ADJUST ; ;

CUSW REL1.3

152: 153: 154: 155: 156: 157: 158: 159:L 160: 161: 162: 163: 164: 165: 166: 167: 168: 169: 170: 171: 172:L 173: 174: 175: 176: 177: 178: 179: 180: 181: 182: 183: 184: 185: 186: 187: 188: 189: 190: 191: 192:L 193: 194: 195: 196: 197: 198: 199: 200: 201:L 202: 203: 204: 205: 206: 207: 208: 209: 210: 211: 212: 213:

!MACRO-Check For Part Present ; Part Present(1) ; ; !Reset At Pickup 1 ; DO[50:AtPickup1]=OFF ; ; !Move Clear Of Pickup 1 ; P[5] 1000mm/sec FINE ; ; !Set Clear Of Pickup 1 ; DO[49:ClrOfPickup1]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference ; !Zone (If Necessary) ; DO[33:RbtClrZone1]=ON ; ; !Move ; P[6] 1000mm/sec FINE ; ; !Insert Process Application ; !as Required ; !CALL (MACRO) ; ; !Wait For Go To Dropoff 1 ; WAIT DI[51:GoToDropoff1]=ON ; ; !MACRO-Zone Check ; !(If Necessary) ; CALL ENTRZON1 ; ; !Reset Clear Of Dropoff 1 ; DO[51:ClrOfDropoff1]=OFF ; ; !Reset Clear To Transfer ; DO[31:CleartoTransfer]=OFF ; ; !Move Over Dropoff 1 ; P[7] 1000mm/sec CNT100 ; ; !MACRO-Verify Correct Tool ; !Call CHK_TOOL ; ; !Set Coll Guard Sensitivity ; COL GUARD ADJUST R[42] ; ; !Move To Dropoff 1 ; P[8] 1000mm/sec FINE ; ; !Set At Dropoff 1 ; DO[52:AtDropoff1]=ON ; ; !Wait for Reposition Tooling ; !WAIT GI[5:ToolingRepod1]=2 ; ; !MACRO-Open the Gripper ; Release Part(1) ; ; !Select Payload Without Parts ; PAYLOAD[2] ;

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104

; !Set Robot UTOOL Number ; UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; !If Necessary ; UFRAME_NUM=1 ; ; !Set Tooling Repositioned ; !GO[2:ReposTooling]=2 ; ; !Move Clr Robot Part Present ; P[9] 1000mm/sec FINE ; ; !MACRO-Verify No Part Present ; Check No Part(1) ; ; !Wait For Exit Dropoff 1 ; !(if necessary) ; WAIT DI[52:ExitDropoff1]=ON ; ; !Reset Coll Guard Sensitivity ; COL GUARD ADJUST ; ; !Reset At Dropoff 1 ; DO[52:AtDropoff1]=OFF ; ; !Reset Tooling Repositioned ; !GO[2:ReposTooling]=0 ; ; !Move Clear Of Dropoff 1 ; P[10] 100% CNT100 ; ; !Set Clear Of Dropoff 1 ; DO[51:ClrOfDropoff1]=ON ; ; !Set Clear Of Interference Zone ; DO[33:RbtClrZone1]=ON ; ; !Move Clear of Transfer ; P[11] 100% FINE ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Reset Robot At Work ; DO[18:RbtAtWork]=OFF ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ; LBL[1000:End] ; ;

CUSW REL1.3

Dispense 1: !Carried Dispense Template ; 2: !******************************** ; 3: !Remove these comments ; 4: !Before Build!!! ; 5: !Rename Program as Necessary ; 6: !Edit Program to Match Part Type ; 7: ; 8: !Modify Zone Numbers and ; 9: !Locations as Required ; 10: ; 11: !Uncomment the MACROs before ; 12: ! finalizing the OLPs ; 13: ; 14: !EXAMPLE PROGRAM ONLY ; 15: !******************************** ; 16: ; 17: !Set Robot Payload ; 18: PAYLOAD[2] ; 19: ; 20: !Set Robot UTOOL Number ; 21: UTOOL_NUM=1 ; 22: ; 23: !Set Robot UFRAME Number ; 24: UFRAME_NUM=1 ; 25: ; 26: !MACRO-Setup App Specific IO ; 27: CALL APP_IO ; 28: ; 29: !Set Acknowledge Style ; 30: GO[1:ActiveStyleBits]=10 ; 31: ; 32: !Reset Coll Guard Sensitivity ; 33: COL GUARD ADJUST ; 34: ; 35: !Reset Clear To Transfer ; 36: DO[31:CleartoTransfer]=OFF ; 37: ; 38: !Move to Pounce ; 39:J P[1] 100% FINE ; 40: ; 41: !Set At Pounce Position Bit ; 42: DO[25:RbtAtPounce]=ON ; 43: ; 44: !Wait For Go To Work ; 45: !or Return Home From Pounce ; 46: WAIT DI[31:GoToWork]=ON OR DI[25:RetFromPounce]=ON ; 47: ; 48: !Check For Go To Work ; 49: IF DI[31:GoToWork]=ON,JMP LBL[20] ; 50: ; 51: !Return Home From Pounce ; 52: CALL MVHMPNCE ; 53: ; 54: !Jump To Program End ; 55: JMP LBL[1000] ; 56: ; 57: LBL[20:Go To Work] ; 58: ; 59: !Set Robot At Work ; 60: DO[18:RbtAtWork]=ON ; 61: ; 62: !Reset Robot At Pounce ; 63: DO[25:RbtAtPounce]=OFF ; 64: ; 65: !MACRO-Zone Check ; 66: !(if necessary) ; 67: !CALL ENTRZON1 ; 68: ; 69: !Pre-process Dispense Equipment ; 70: !(insert statements) ; 71: ; 72: !Wait for Dispenser Ready ; 73: WAIT (DI[385:Dsp1DispenRdy]=ON) ; 74: ;

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105

!Set Disp Robot in Process ; DO[393:Disp1RbtinPrc]=ON ; ; WAIT .10(sec) ; ; !Set Dispense Style ; GO[31:Disp1StyBits]=1 ; ; WAIT .10(sec) ; ; !Set Disp Style Strobe ; DO[394:Disp1StyStrobe]=ON ; ; !Wait for Disp in Process ; WAIT DI[386:Dsp1DispenInPrc]=ON ; !Reset Dispense Style ; GO[31:Disp1StyBits]=0 ; ; !Reset Disp Style Strobe ; DO[394:Disp1StyStrobe]=OFF ; ; !Set Coll Guard Sensitivity ; COL GUARD ADJUST R[42] ; ; !Move Seal Start, Turn On Gun ; P[2] 1000mm/sec CNT100 SS[1] ; !Move along Path ; P[3] 1000mm/sec CNT100 ; ; !Move To Seal End, Turn Off Gun P[4] 1000mm/sec CNT100 SE ; ; !Move Clear of Part ; P[5] 1000mm/sec FINE ; ; !Reset Coll Guard Sensitivity ; COL GUARD ADJUST ; ; !Set Dispense Complete ; DO[401:Disp1Complete]=ON ; ; !Wait for Dispense Vol. OK ; WAIT DI[387:Dsp1VolumeOK]=ON ; !Reset Dispense Complete ; DO[401:Disp1Complete]=OFF ; ; !Reset Disp Robot in Process ; DO[393:Disp1RbtinPrc]=OFF ; ; !Post-process Dispense Equip ; !(insert statements) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference Zone DO[33:RbtClrZone1]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ; LBL[1000:End] ; ;

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CUSW REL1.3

Spot Welding 1: !Carried Spot Welding Template ; 2: !******************************** ; 3: !Remove these comments ; 4: !Before Build!!! ; 5: !Rename Program as Necessary ; 6: !Edit Program to Match Part Type ; 7: ; 8: !Modify Zone Numbers and ; 9: !Locations as Required ; 10: ; 11: !Uncomment the MACROs before ; 12: ! finalizing the OLPs ; 13: ; 14: !EXAMPLE PROGRAM ONLY ; 15: !******************************** ; 16: ; 17: !Set Robot Payload ; 18: PAYLOAD[2] ; 19: ; 20: !Set Robot UTOOL Number ; 21: UTOOL_NUM=1 ; 22: ; 23: !Set Robot UFRAME Number ; 24: UFRAME_NUM=1 ; 25: ; 26: !MACRO-Setup App Specific IO ; 27: CALL APP_IO ; 28: ; 29: !Set Acknowledge Style ; 30: GO[1:ActiveStyleBits]=1 ; 31: ; 32: !Reset Clear To Transfer ; 33: DO[31:CleartoTransfer]=OFF ; 34: ; 35: !Move to Pounce ; 36:J P[1] 100% FINE ; 37: ; 38: !Set At Pounce Position Bit ; 39: DO[25:RbtAtPounce]=ON ; 40: ; 41: !Wait For Go To Work ; 42: !or Return Home From Pounce ; 43: WAIT DI[31:GoToWork]=ON OR DI[25:RetFromPounce]=ON ; 44: ; 45: !Check For Go To Work ; 46: IF DI[31:GoToWork]=ON,JMP LBL[20] ; 47: ; 48: !Return Home From Pounce ; 49: CALL MVHMPNCE ; 50: ; 51: !Jump To Program End ; 52: JMP LBL[1000] ; 53: ; 54: LBL[20:Go To Work] ; 55: ; 56: !Set Robot At Work ; 57: DO[18:RbtAtWork]=ON ; 58: ; 59: !Reset Robot At Pounce ; 60: DO[25:RbtAtPounce]=OFF ; 61: ; 62: !MACRO-Zone Check ; 63: !(if necessary) ; 64: CALL ENTRZON1 ; 65: ; 66: !Move to Weld 1 ; 67: !insert motion if necessary ; 68:L P[2] 1000mm/sec FINE ; 69: ; 70: !Select Schedule Weld 1 ;

AS OF 1/12/2012 Printed copies are not source controlled

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106

P[3] 100mm/sec FINE SPOT[SD=1,P=1,S=1,ED=1] ; ; !Move to Weld 2 ; !insert motion if necessary ; P[4] 1000mm/sec FINE ; ; !Select Schedule Weld 2 ; P[5] 100mm/sec FINE SPOT[SD=1,P=1,S=1,ED=1] ; ; !Move Clear of Clamps ; P[6] 1000mm/sec FINE ; ; !Set Clear to Unclamp Early ; DO[65:Clr2UnclampEarly]=ON ; ; !Check for Tip Dress Req ; IF DI[28:TipDressGunReq]=ON,JMP LBL[30] ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference Zone ; DO[33:RbtClrZone1]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ; JMP LBL[1000] ; ; LBL[30] ; ; !Move Clear of Transfer ; !To Tip Dress ; P[7] 50% FINE ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference Zone ; DO[33:RbtClrZone1]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ; !MACRO-Tip Dress Gun 1 ; CALL TPDRSGN1(62) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; CALL WR_UPDAT(1,0) ; ; LBL[1000:End] ;

CUSW REL1.3

Stud Welding 1: !Carried Stud Welding Template ; 2: !******************************** ; 3: !Remove these comments ; 4: !Before Build!!! ; 5: !Rename Program as Necessary ; 6: !Edit Program to Match Part Type ; 7: ; 8: !Modify Zone Numbers and ; 9: !Locations as Required ; 10: ; 11: !Uncomment the MACROs before ; 12: ! finalizing the OLPs ; 13: ; 14: !EXAMPLE PROGRAM ONLY ; 15: !******************************** ; 16: ; 17: !Set Robot Payload ; 18: PAYLOAD[2] ; 19: ; 20: !Set Robot UTOOL Number ; 21: UTOOL_NUM=1 ; 22: ; 23: !Set Robot UFRAME Number ; 24: UFRAME_NUM=1 ; 25: ; 26: !MACRO-Setup App Specific IO ; 27: CALL APP_IO ; 28: ; 29: !Set Acknowledge Style ; 30: GO[1:ActiveStyleBits]=1 ; 31: ; 32: !Reset Clear To Transfer ; 33: DO[31:CleartoTransfer]=OFF ; 34: ; 35: !Move to Pounce ; 36:J P[1] 100% FINE ; 37: ; 38: !Set At Pounce Position Bit ; 39: DO[25:RbtAtPounce]=ON ; 40: ; 41: !Wait For Go To Work ; 42: !or Return Home From Pounce ; 43: WAIT DI[31:GoToWork]=ON OR DI[25:RetFromPounce]=ON ; 44: ; 45: !Check For Go To Work ; 46: IF DI[31:GoToWork]=ON,JMP LBL[20] ; 47: ; 48: !Return Home From Pounce ; 49: CALL MVHMPNCE ; 50: ; 51: !Jump To Program End ; 52: JMP LBL[1000] ;

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107

; LBL[20:Go To Work] ; ; !Set Robot At Work ; DO[18:RbtAtWork]=ON ; ; !Reset Robot At Pounce ; DO[25:RbtAtPounce]=OFF ; ; !MACRO-Zone Check ; !(if necessary) ; CALL ENTRZON1 ; ; !Move to Weld 1 ; !insert motion if necessary ; P[2] 1000mm/sec FINE ; ; !Select Schedule Weld 1 ; P[3] 100mm/sec FINE SPOT[S=1] ; ; !Move to Weld 2 ; !insert motion if necessary ; P[4] 1000mm/sec FINE ; ; !Select Schedule Weld 2 ; P[5] 100mm/sec FINE SPOT[S=1] ; ; !Move Clear of Clamps ; P[6] 1000mm/sec FINE ; ; !Set Clear to Unclamp Early ; DO[65:Clr2UnclampEarly]=ON ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference Zone ; DO[33:RbtClrZone1]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ;

CUSW REL1.3

Tip Change (Style #3) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 37: 37: 37: 38: 39: 40:

!Tip Change Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ; UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=3 ; ; !Insert Dress Approach Movement ; !(if necessary) ; ; !MACRO-Tip Dress Gun 1 ; CALL TPDRSGN1(0) ; ; !Wait for TipDressComplete ; WAIT (1) sec. ; ; !Reset Tip Dress Complete ; DO[29:TipDressComplt]=OFF ; ;

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!Move to Tip Change Position ; P[1] 100% FINE ; ; !Set Robot at Service ; DO[26:RbtAtService]=ON ; ; !Set Ready for Tip Change ; DO[30:RdyForTipChg]=ON ; ; !Wait for Service Complete ; WAIT (DI[26:ServiceCompltReq]=ON) ; ; !Reset Robot at Service ; DO[26:RbtAtService]=OFF ; ; !Reset Ready for Tip Change ; DO[30:RdyForTipChg]=OFF ; ; !MACRO-Reset Stepper ; CALL RST_STPR ; ; !MACRO-Seat Caps Gun 1 ; CALL TW_PRSRT(1,500,2,4,1,10,5,15) ; ; !Tip Wear Compensation Gun 1 ; CALL WR_UPDAT(1,0) ; ; !Insert Dress Approach Movement ; !(if necessary) ; ; !Pulse W1 Reset Water Saver ; DO[586:W1RstWtrSvr]=PULSE,1.0sec ; ; !Wait for WaterOK ; WAIT (DI[785:W1OKtoWeld]=ON) ; ; !MACRO-Tip Dress Gun 1 ; CALL TPDRSGN1(62) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

Purge (Style #4) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23:

!Purge Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=3 ; ; !Set Ext Purge 1 in Progress ;

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108

DO[97:ExtPurg1InProgrs]=ON ; ; !Pre-process Dispense Equipment ; !(insert statements) ; ; !Turn On Gun-Purge Schedule ; DO[416:Disp1Purge]=ON ; ; !Wait 'X' Seconds ; WAIT 7.00(sec) ; ; !Turn Off Gun ; DO[416:Disp1Purge]=OFF ; ; !Post-process Disp Equipment ; !(insert statements) ; ; !Reset Ext Purge 1 in Progress ; DO[97:ExtPurg1InProgrs]=OFF ; ; !MACRO-Home IO (if necessary) ; CALL HOME_IO ; ;

CUSW REL1.3

Tip Burn In (Style #5) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20:

!Tip Burn In Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ;

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UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=5 ; ; !Move to Service Position ; !if necessary ; PR[5] 100% FINE ; ; !MACRO-Tip Burn In ; CALL TPBURNIN ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !MACRO-Home IO ; CALL MOVE_IO ;

Service Program (Style #6) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23:

!Service Program Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ; UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ;

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UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=6 ; ; !Move to Service Position ; PR[5] 100% FINE ; ; !Set Robot at Service ; DO[26:RbtAtService]=ON ; ; !Wait for Service Complt Req ; WAIT (DI[26:ServiceCompltReq]=ON) ; !Reset Robot at Service ; DO[26:RbtAtService]=OFF ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

;

Tip Dress Gun 1 (Style #7) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20:

!Tip Dress 1st Gun Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ;

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109

UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=7 ; ; !Insert Approach Movement ; !(if necessary) ; ; !MACRO-Tip Dress Gun 1 ; CALL TPDRSGN1(60) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

CUSW REL1.3

Tip Dress Gun 2 (Style #8) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20:

!Tip Dress 2nd Gun Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ;

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UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=8 ; ; !Insert Approach Movement ; !(if necessary) ; ; !MACRO-Tip Dress Gun 2 ; CALL TPDRSGN2(61) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

Tool Change (Style #9) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20:

!Tool Change Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ;

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110

UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=9 ; ; !Set Desired Tool ID ; R[2]=GI[4:PickToolBits] ; ; !MACRO-Check Tool on Wrist ; CALL CHK_TOOL ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

CUSW REL1.3

Check ATI Errors (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40: 41: 42: 43: 44: 45: 46: 47: 48: 49: 50: 51: 52: 53: 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67: 68: 69: 70: 71: 72: 73: 74: 75:

!****************************** ; !MACRO CHECK ATI ERRORS ; !****************************** ; !Parameters: AR[] ; !1: Current Sequence ; !****************************** ; ; !Jump to Current Sequence ; R[16]=AR[1] ; JMP LBL[R[16]] ; ; !****************************** ; !READY TO PICK/LATCH/UNLATCH ; !****************************** ; LBL[1:ReadyToPick] ; LBL[3:Latch] ; LBL[7:Unlatch] ; ; !Set ATI Recovery Method ; R[17]=1 ; ; IF (DI[648:RTLMismatch]),JMP LBL[648] ; IF (DI[649:TSIVMismatch]),JMP LBL[649] ; IF (DI[650:LatchOverLoad]),JMP LBL[650] ; IF (DI[651:UnlatchOverLoad]),JMP LBL[651] ; IF (DI[652:SpareOverload]),JMP LBL[652] ; IF (DI[659:TSIVFault]),JMP LBL[659] ; IF (DI[660:RTLFault]),JMP LBL[660] ; IF (DI[653:RTLrtlvMismatch]),JMP LBL[653] ; IF (DI[654:TSIVtsrvMismatch]),JMP LBL[654] ; IF (DI[655:UnsafeUnlatch]),JMP LBL[655] ; IF (DI[656:LckUnlckSensFlt]),JMP LBL[656] ; IF (DI[657:LatchNotComplt]),JMP LBL[657] ; IF (DI[658:UnlatchNotComplt]),JMP LBL[658] ; ; !OK - Exit ; JMP LBL[999] ; ; !****************************** ; !READY TO LATCH ; !****************************** ; LBL[2:ReadyToLatch] ; ; !Set ATI Recovery Method ; R[17]=0 ; ; IF (!DI[636:ReadyToLock1]),JMP LBL[636] ; IF (!DI[637:ReadyToLock2]),JMP LBL[637] ; ; !OK - Exit ; JMP LBL[999] ; ; !****************************** ; !EXIT PICK/RDY TO DROP/EXT DROP ; !****************************** ; LBL[4:ExitPick] ; LBL[5:ReadyToDrop] ; LBL[8:ExitDrop] ; ; !Set ATI Recovery Method ; R[17]=0 ; ; IF (DI[648:RTLMismatch]),JMP LBL[648] ; IF (DI[649:TSIVMismatch]),JMP LBL[649] ; IF (DI[650:LatchOverLoad]),JMP LBL[650] ; IF (DI[651:UnlatchOverLoad]),JMP LBL[651] ; IF (DI[652:SpareOverload]),JMP LBL[652] ; IF (DI[659:TSIVFault]),JMP LBL[659] ; IF (DI[660:RTLFault]),JMP LBL[660] ; IF (DI[653:RTLrtlvMismatch]),JMP LBL[653] ; IF (DI[654:TSIVtsrvMismatch]),JMP LBL[654] ; IF (DI[655:UnsafeUnlatch]),JMP LBL[655] ; IF (DI[656:LckUnlckSensFlt]),JMP LBL[656] ; IF (DI[657:LatchNotComplt]),JMP LBL[657] ; IF (DI[658:UnlatchNotComplt]),JMP LBL[658] ;

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111

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; !OK - Exit ; JMP LBL[999] ; ; !****************************** ; !READY TO UNLATCH ; !****************************** ; LBL[6:ReadyToUnlatch] ; ; !Set ATI Recovery Method ; R[17]=0 ; ; IF (!DI[640:ToolStndIntlkV1]),JMP LBL[640] ; IF (!DI[641:ToolStndIntlkV2]),JMP LBL[641] ; ; !OK - Exit ; JMP LBL[999] ; ; !****************************** ; !ERROR HANDLING ; !****************************** ; ; !AUX POWER ; LBL[635] ; UALM[7] ; JMP LBL[900] ; ; !READY TO LOCK1 ; LBL[636] ; UALM[8] ; JMP LBL[900] ; ; !READY TO LOCK2 ; LBL[637] ; UALM[9] ; JMP LBL[900] ; ; !TOOL STAND INTERLOCK1 ; LBL[640] ; UALM[10] ; JMP LBL[900] ; ; !TOOL STAND INTERLOCK2 ; LBL[641] ; UALM[11] ; JMP LBL[900] ; ; !RTL MISMATCH ; LBL[648] ; UALM[12] ; JMP LBL[900] ; ; !TSIV MISMATCH ; LBL[649] ; UALM[13] ; JMP LBL[900] ; ; !LATCH OVERLOAD ; LBL[650] ; UALM[14] ; JMP LBL[900] ; ; !UNLATCH OVERLOAD ; LBL[651] ; UALM[15] ; JMP LBL[900] ; ; !SPARE OVERLOAD ; LBL[652] ; UALM[16] ; JMP LBL[900] ; ; !RTLRTLV MISMATCH ; LBL[653] ; UALM[17] ;

CUSW REL1.3

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JMP LBL[900] ; ; !TSIVTSRV MISMATCH ; LBL[654] ; UALM[18] ; JMP LBL[900] ; ; !UNSAFE UNLATCH ; LBL[655] ; UALM[19] ; JMP LBL[900] ; ; !LOCK UNLOCK SENSOR FAULT ; LBL[656] ; UALM[20] ; JMP LBL[900] ; ; !LATCH NOT COMPLETE ; LBL[657] ; UALM[21] ; JMP LBL[900] ; ; !UNLATCH NOT COMPLETE ; LBL[658] ; UALM[22] ; JMP LBL[900] ; ; !TSIV FAULT ; LBL[659] ; UALM[23] ; JMP LBL[900] ; ; !RTL FAULT ; LBL[660] ; UALM[24] ; JMP LBL[900] ; ; !****************************** ;

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!RECOVERY ; !****************************** ; ; LBL[900:Recovery] ; ; !Check Recovery Type ; IF R[17]=1,JMP LBL[910] ; ; !Set Clear Errors ; DO[635:ClearErrs]=ON ; ; !Wait 2 Seconds ; WAIT 2.00(sec) ; ; !Reset Clear Errors ; DO[635:ClearErrs]=OFF ; ; !Retry ; JMP LBL[R[16]] ; ; LBL[910] ; ; !Reset Latch and Unlatch Tool ; DO[632:LatchOrLock]=OFF ; DO[633:UnlatchOrUnlock]=OFF ; ; !Set Clear Errors ; DO[635:ClearErrs]=ON ; ; !Wait 2 Seconds ; WAIT 2.00(sec) ; ; !Reset Clear Errors ; DO[635:ClearErrs]=OFF ; ; LBL[999:End] ; ;

Check Tool (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16:

!****************************** ; !MACRO CHECK TOOL ON WRIST ; !****************************** ; ; LBL[1:Verify Tool] ; ; !Set Current Tool ID and ; !Line Number ; R[1]=(GI[41:ToolIDswtch1Bits]) ; R[8]=(GI[45:ToolIDSwtch5Bits]) ; GO[3:ToolIDOnWrstBits]=R[1] ; ; !Is Tool ID Correct? ; IF R[1]=R[2],JMP LBL[999] ; ; !Is Tool on Wrist? ;

AS OF 1/12/2012 Printed copies are not source controlled

17: LBL[2] 18: 19: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33:

112

IF (!DI[644:ToolPresent] AND R[1]=15),JMP ; ; !Drop Prep and Drop Tool ; CALL PREPDROP ; ; JMP LBL[1] ; ; LBL[2:Pick Tool] ; ; !Select Pick Fixture & Pick ; CALL PREPPICK ; ; JMP LBL[1] ; ; LBL[999:End] ; ;

CUSW REL1.3

Drop Tool Nest 1 (Macro) 1: !****************************** ; 2: !MACRO DROP TOOL IN NEST 1 ; 3: !****************************** ; 4: ; 5: UTOOL_NUM=5 ; 6: UFRAME_NUM=0 ; 7: ; 8: DO[635:ClearErrs]=PULSE,1.0sec ; 9: ; 10: !Set Request to Enter Tool Nest ; 11: DO[71:Req2EntrToolNest]=ON ; 12: ; 13: !Wait Clear to Enter Tool Nest ; 14: WAIT DI[81:Clr2EntToolNest]=ON ; 15: ; 16: !Reset Clear of Tool Nest ; 17: DO[72:ClearOfToolNest]=OFF ; 18: ; 19: !Reset Request to Enter Nest ; 20: DO[71:Req2EntrToolNest]=OFF ; 21: ; 22: !MACRO-Set Tool Device Offline ; 23: CALL DV_OFFLN(2,31,10) ; 23: CALL DV_OFFLN(2,39,10) ; 24: ; 25: !Move to Tool Nest Perch/Approach ; 26:J P[3:Perch In] 100% FINE ; 27: ; 28: !PR[111:ToolOffset1] ; 29: !X=-150 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 30:L PR[101:ToolNest1Drop] 1200mm/sec FINE Tool_Offset,PR[111:ToolOffset1] : ; 31: ; 32: !PR[112:ToolOffset2] ; 33: !X=-5 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 34:L PR[101:ToolNest1Drop] 200mm/sec FINE Tool_Offset,PR[112:ToolOffset2] : ; 35: ; 36: !PR[113:ToolOffset3] ; 37: !X=0 Y=0 Z=25 Rx=0 Ry=0 Rz=0 ; 38:L PR[101:ToolNest1Drop] 50mm/sec FINE Tool_Offset,PR[113:ToolOffset3] : ; 39: ; 40: !MACRO-ATI State Check - Seq5 ; 41: IF DO[645:GeneralFaults]=ON,CALL ATI_CHCK(5) ; 42: ; 43: !Reset Out of Nest ; 44: DO[637:OutOfNest]=OFF ; 45: ; 46: !Move to Tool Nest ; 47: UTOOL_NUM=5 ; 48:L PR[101:ToolNest1Drop] 50mm/sec FINE ; 49: ; 50: !Wait for Tool in Nest 1 ; 51: WAIT DI[73:ToolInNest1]=ON ; 52: ; 53: !MACRO-ATI State Check - Seq6 ; 54: CALL ATI_CHCK(6) ; 55: ; 56: LBL[7:RetryATISeq7] ; 57: ; 58: !Reset Latch Tool ; 59: DO[632:LatchOrLock]=OFF ; 60: ; 61: !Set Unlatch Tool ; 62: DO[633:UnlatchOrUnlock]=ON ; 63: ; 64: !Wait for ATI switches to settle in ; 64: WAIT DI[633:ToolUnLocked]=ON TIMEOUT,LBL[633] ; 65: LBL[633] ; 66: ;

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113

67: !Wait for ATI ; 68: WAIT ((DI[633:ToolUnLocked] AND !DI[632:ToolLocked]) OR : DO[645:GeneralFaults]) ; 69: ; 70: !Check for Errors ; 71: IF DO[645:GeneralFaults]=OFF,JMP LBL[17] ; 72: ; 73: !MACRO-ATI State Check - Seq7 ; 74: CALL ATI_CHCK(7) ; 75: ; 76: JMP LBL[7] ; 77: ; 78: LBL[17:ATIUnlocked] ; 79: ; 80: !Set Payload Without Tool ; 81: PAYLOAD[2] ; 82: ; 83: UTOOL_NUM=9 ; 84: UFRAME_NUM=0 ; 85: ; 86:L PR[106:ToolNest1Pick] 150mm/sec FINE ; 87: ; 87: !Move Clear of Tool in Nest IO ; 88: !PR[114:ToolOffset4] ; 89: !X=0 Y=0 Z=-15 Rx=0 Ry=0 Rz=0 ; 90:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[114:ToolOffset4] : ; 91: ; 92: !Wait for Tool in Nest 1 ; 93: !Check for Disengagement ; 94: !of Tool Changer ; 95: WAIT DI[73:ToolInNest1]=ON ; 96: ; 97: !MACRO-ATI State Check - Seq8 ; 98: IF DO[645:GeneralFaults]=OFF,JMP LBL[8] ; 99: ; 100: !MACRO-ATI State Check ; 101: CALL ATI_CHCK(8) ; 102: ; 103: !Wait for Tool in Nest 1 ; 104: !Check for Disengagement ; 105: !of Tool Changer ; 106: WAIT DI[73:ToolInNest1]=ON ; 107: ; 108: LBL[8] ; 109: !Clear of Tool in Nest ; 110: ; 111: !PR[115:ToolOffset5] ; 112: !X=0 Y=0 Z=-155 Rx=0 Ry=0 Rz=0 ; 113:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[115:ToolOffset5] : ; 114: ; 115: !Reset Unlatch Tool ; 116: DO[633:UnlatchOrUnlock]=OFF ; 117: ; 118: !Set Out of Nest ; 119: DO[637:OutOfNest]=ON ; 120: ; 121: !Clear Ati Errors ; 122: DO[635:ClearErrs]=PULSE,1.0sec ; 123: ; 124: UTOOL_NUM=9 ; 125: UFRAME_NUM=0 ; 126: ; 127: !Move Clear of Tool Nest ; 128:J P[2:Perch Out] 50% FINE ;

CUSW REL1.3

Pick Tool Nest 1 (Macro) 1: !****************************** ; 2: !MACRO PICK TOOL FROM NEST 1 ; 3: !****************************** ; 4: ; 5: UTOOL_NUM=9 ; 6: UFRAME_NUM=0 ; 7: ; 8: !Move to Tool Nest Perch ; 9:J P[1:Perch In] 100% FINE ; 10: ; 11: !Clear Ati Errors ; 12: DO[635:ClearErrs]=PULSE,1.0sec ; 13: ; 14: !Set Request to Enter Tool Nest ; 15: DO[71:Req2EntrToolNest]=ON ; 16: ; 17: !Wait Clear to Enter Tool Nest ; 18: WAIT DI[81:Clr2EntToolNest]=ON ; 19: ; 20: !Reset Clear of Tool Nest ; 21: DO[72:ClearOfToolNest]=OFF ; 22: ; 23: !Reset Request to Enter Nest ; 24: DO[71:Req2EntrToolNest]=OFF ; 25: ; 26: ! 27: ; 28: !Move Clear of Tool in Nest IO ; 29: !PR[115:ToolOffset5] ; 30: !X=0 Y=0 Z=-155 Rx=0 Ry=0 Rz=0 ; 31:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[115:ToolOffset5] : ; 32: ; 33: !PR[116:ToolOffset6] ; 34: !X=0 Y=0 Z=-50 Rx=0 Ry=0 Rz=0 ; 35:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[116:ToolOffset6] : ; 36: !Reset Out of Nest ; 37: DO[637:OutOfNest]=OFF ; 38: ; 39: LBL[10] ; 40: ; 41: !Check ATI Sensor States ; 42: WAIT (!DI[632:ToolLocked] AND !DI[633:ToolUnLocked]) TIMEOUT,LBL[90] ; 43: ; 44: LBL[1:RetryATISeq1] ; 45: ; 46: !Reset Latch Tool ; 47: DO[632:LatchOrLock]=OFF ; 48: ; 49: !Set Unlatch Tool ; 50: DO[633:UnlatchOrUnlock]=ON ; 51: ; 52: WAIT DI[633:ToolUnLocked]=ON TIMEOUT,LBL[633] ; 53: LBL[633] ; 54: ; 55: !Wait for ATI Feedback ; 56: WAIT (DI[633:ToolUnLocked] OR DO[645:GeneralFaults]) ; 57: ; 58: !Check for General Errors ; 59: IF DO[645:GeneralFaults]=OFF,JMP LBL[11] ; 60: ; 61: !ATI State Check - Seq1 ; 62: CALL ATI_CHCK(1) ; 63: ; 64: JMP LBL[1] ; 65: ; 66: LBL[11:ToolUnlocked] ; 67: ; 68: !Move to Tool Nest ; 69: ; 70: !PR[117:ToolOffset7] ;

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114

71: !X=0 Y=0 Z=-25 Rx=0 Ry=0 Rz=0 ; 72:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[117:ToolOffset7] : ; 73:L PR[106:ToolNest1Pick] 50mm/sec FINE ; 74: ; 75: !ATI State Check - Seq2 ; 76: CALL ATI_CHCK(2) ; 77: ; 78: LBL[3:RetryATISeq3] ; 79: ; 80: !Reset Unlatch Tool ; 81: DO[633:UnlatchOrUnlock]=OFF ; 82: ; 83: !Set Latch Tool ; 84: DO[632:LatchOrLock]=ON ; 85: ; 86: !MACRO-Set Tool Devices Online ; 87: CALL DV_ONLN(2,31,0) ; 87: CALL DV_ONLN(2,39,0) ; 88: ; 89: WAIT DI[632:ToolLocked]=ON TIMEOUT,LBL[632] ; 90: LBL[632] ; 91: ; 92: !Wait for ATI ; 93: WAIT ((DI[632:ToolLocked] AND !DI[633:ToolUnLocked]) OR : DO[645:GeneralFaults]) ; 94: ; 95: !Check for Errors ; 96: IF DO[645:GeneralFaults]=OFF,JMP LBL[13] ; 97: ; 98: !ATI State Check - Seq3 ; 99: CALL ATI_CHCK(3) ; 100: ; 101: JMP LBL[3] ; 102: ; 103: LBL[13:ToolLocked] ; 104: ; 105: !Set Payload With Tool ; 106: PAYLOAD[1] ; 107: ; 108: !Verify Tool ID ; 109: IF GI[41:ToolIDswtch1Bits]R[2:Desired Tool ID],JMP LBL[6] ; 110: ; 111: !Set Frames with new Tool ; 111: UTOOL_NUM=5 ; 112: UFRAME_NUM=0 ; 113: ; 114: !Move Clear of Tool in Nest IO ; 115:L PR[6:ToolNest1] 50mm/sec FINE ; 116: ; 117: !PR[113:ToolOffset3] ; 118: !X=0 Y=0 Z=25 Rx=0 Ry=0 Rz=0 ; 119:L PR[101:ToolNest1Drop] 50mm/sec FINE Tool_Offset,PR[113:ToolOffset3] : ; 120: !ATI State Check - Seq4 ; 121: IF DO[645:GeneralFaults]=ON,CALL ATI_CHCK(4) ; 122: ; 123: !Set Out of Nest ; 124: DO[637:OutOfNest]=ON ; 125: ; 126: !PR[112:ToolOffset2] ; 127: !X=-5 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 128:L PR[101:ToolNest1Drop] 200mm/sec FINE Tool_Offset,PR[112:ToolOffset2] : ; 129: !Move Clear Tool Nest ; 130: ; 131: !PR[111:ToolOffset1] ; 132: !X=-150 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 133:L PR[101:ToolNest1Drop] 1200mm/sec FINE Tool_Offset,PR[111:ToolOffset1] : ;

CUSW REL1.3

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!Set Frames with new Tool again ; UTOOL_NUM=5 ; UFRAME_NUM=0 ; ; !Move to Tool Nest Perch ; P[2:Perch Out] 2000mm/sec FINE ; ; !Check If Device Is Online ; CALL DV_STCHK(2,31,3) ; IF R[3:Devnet Status]=2,JMP LBL[99] ; ; !Set Device Online ; CALL DV_ONLN(2,31,30) ; JMP LBL[99] ; ;

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115

LBL[6:ToolIDMismatch] ; ; !User Alarm - Unrecognized ; !Tool on End-effector ; UALM[1] ; ABORT ; ; LBL[90:ATILockUnlockSns] ; ; !User Alarm - Lock or Unlock ; !Sensor Incorrect State ; UALM[26] ; JMP LBL[10] ; ; LBL[99:End] ;

CUSW REL1.3

Enter Zone 1 (Macro) 1: 2: 3: 4: 5:

!****************************** ; !Enter Zone 1 Macro ; !****************************** ; ; !Reset Clear of Zone 1 ;

1: 2: 3: 4: 5: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35:

!****************************** ; !MACRO Setup Outputs ; !****************************** ; ; GO[1:ActiveStyle]=0 ; ; DO[18:RbtAtWork]=OFF ; DO[19:WorkComplete]=OFF ; DO[25:RbtAtPounce]=OFF ; DO[26:RbtAtService]=OFF ; DO[28RbtInTipDress]=OFF ; DO[29:TipDressComplt]=OFF ; DO[31:ClearToTransfer]=ON ; ; !Zones ; DO[33:RbtClrZone1]=ON ; DO[34:RbtClrZone2]=ON ; DO[35:RbtClrZone3]=ON ; DO[36:RbtClrZone4]=ON ; DO[37:RbtClrZone5]=ON ; DO[38:RbtClrZone6]=ON ; DO[39:RbtClrZone7]=ON ; DO[40:RbtClrZone8]=ON ; ; !Pickup/Dropoff ; DO[49:ClrOfPickup1]=ON ; DO[50:AtPickup1]=OFF ; DO[51:ClrOfDropoff1]=ON ; DO[52:AtDropoff1]=OFF ; DO[53:ClrOfPickup2]=ON ; DO[54:AtPickup2]=OFF ; DO[55:ClrOfDropoff2]=ON ; DO[56:AtDropoff2]=OFF ; DO[57:ClrOfPickup3]=ON ;

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DO[33:RobotClrZone1]=OFF ; ; !Wait for OK To Enter Zone 1 ; WAIT DI[33:Zone1ClrToEnter]=ON ; ;

Home IO (Macro)

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116

DO[58:AtPickup3]=OFF ; DO[59:ClrOfDropoff3]=ON ; DO[60:AtDropoff3]=OFF ; DO[61:ClrOfPickup4]=ON ; DO[62:AtPickup4]=OFF ; DO[63:ClrOfDropoff4]=ON ; DO[64:AtDropoff4]=OFF ; ; DO[65:Clr2UnclampEarly]=OFF; DO[71:Req2ToEnterTN]=OFF ; DO[72:ClrOfToolNest]=ON ; DO[89:PickOverride]=OFF ; DO[94:AbortPickReq]=OFF ; DO[102:StepperRst1Ack]=OFF ; DO[103:StepperRst2Ack]=OFF ; DO[104:TipBurnInComplt]=OFF ; DO[105:RbtClrFixt1]=ON ; DO[106:RbtClrFixt2]=ON ; DO[107:RbtClrFixt3]=ON ; GO[2:ReposTooling]=0 ; ; GO[31:Disp1StyleBits]=0 ; DO[393:Disp1RbtinPrc]=OFF ; DO[394:Disp1StyStrobe]=OFF ; DO[401:Disp1Complete]=OFF ; ; DO[637:OutOfNest]=ON ; DO[640:ToolNotPresent]=OFF ; DO[641:InvalidToolReqd]=OFF ; DO[642:UnxpctdToolPrsnt]=OFF ; DO[643:Nest not Empty]=OFF ; DO[644:Nest is Empty]=OFF ; ;

CUSW REL1.3

Process Application – Ped Spot (Macro) 1: 2: 3: 4: 5: 6: 7:L 8: 9: 10:L : 11: 12: 13: 14:L 15: 16: 17:L : 18: 19: 20:L 21: 22: 23: 24: 25:

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!****************************** ; !MACRO PED SPOT WELD; !****************************** ; ; !Move to Weld 1 ; !insert motion if necessary ; P[1] 1000mm/sec FINE ; ; !Select Schedule Weld 1 ; P[2] 100mm/sec FINE SPOT[SD=1,P=1,S=1,ED=1] ; ; !Move to Weld 2 ; !insert motion if necessary ; P[3] 1000mm/sec FINE ; ; !Select Schedule Weld 2 ; P[4] 100mm/sec FINE SPOT[SD=1,P=1,S=1,ED=1] ; ; !Move Clear of Ped Welder ; P[5] 1000mm/sec FINE ; ; LBL[20] ; ; !Dropoff/Tip Change/Tip Dress ; WAIT (DI[51:GoToDropoff1]=ON OR DI[28:TipDressGunReq]=ON OR DI[105:TipChangeReq]=ON OR DI[104: TipBurnInReq]=ON OR DI[27: ServiceRequest]=ON); ; !Check for Tip Change ; IF DI[105:TipChangeReq]=ON,JMP LBL[30] ; ; !Check for Tip Dress ; IF DI[28:TipDressGunReq]=ON,JMP LBL[40] ; ; !Check for Tip Burn In ; IF DI[104:TipBurnInReq]=ON,JMP LBL[50] ; ; !Check for Service Request ; IF DI[27:ServiceRequest]=ON,JMP LBL[60] ; !Check for go to Dropoff ; IF DI[51:GoToDropoff1]=ON,JMP LBL[70] ;

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117

; !****************************** LBL[30:TipChange] ; ; !MACRO-Tip Dress Ped ; CALL TPDRSPD(0) ; ; !Reset Tip Dress Complete ; DO[29:TipDressComplt]=OFF ; ; !MACRO-Tip Change Ped ; CALL TPCHGPD ; ; !MACRO-Tip Dress Ped ; CALL TPDRSPD(58) ; ; JMP LBL[20] ; ; !****************************** LBL[40:TipDress] ; ; !MACRO-Tip Dress Ped ; CALL TPDRSPD(62) ; ; JMP LBL[20] ; ; !****************************** LBL[50:TipBurnIn] ; ; !MACRO-Tip Burn In ; CALL TPBURNIN ; ; JMP LBL[20] ; ; !****************************** LBL[60:Service_W_Part] ; ; !MACRO-Srv_With_Prt ; CALL Srv_With_Prt ; ; JMP LBL[20] ; ; !****************************** LBL[70:Dropoff] ; ;

;

;

;

;

;

CUSW REL1.3

Process Application – Ped Dispense (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37:L 38: 39: 40:L 41:

!****************************** ; !MACRO PED DISPENSE ; !****************************** ; ; !Pre-processing for Disp Equip ; !Insert Statements ; ; !Wait for Dispenser Ready ; WAIT (DI[385:Dsp1DispenRdy]=ON) ; !Set Disp Robot in Process ; DO[393:Disp1RbtinPrc]=ON ; ; WAIT .10(sec) ; ; !Set Dispense Style ; GO[31:Disp1StyBits]=1 ; ; WAIT .10(sec) ; ; !Set Disp Style Strobe ; DO[394:Disp1StyStrobe]=ON ; ; !Wait for Disp in Process ; WAIT DI[386:Dsp1DispenInPrc]=ON ; !Reset Dispense Style ; GO[31:Disp1StyBits]=0 ; ; !Reset Disp Style Strobe ; DO[394:Disp1StyStrobe]=OFF ; ; !Set Coll Guard Sensitivity ; COL GUARD ADJUST R[42] ; ; !Move Seal Start, Turn On Gun ; P[1] 1000mm/sec CNT100 SS[1] ; ; !Move along Path ; P[2] 100mm/sec CNT100 ; ;

AS OF 1/12/2012 Printed copies are not source controlled

;

Example: SS[1] –seal schedule is using BW TCPP (robot tool center point position) changes digital ; IO per robot speed. In the SS command use the following per robot speed 500mm/sec: 200mm=10volt 100mm=5volts OR Change SS[1] flow rate to be direct voltage

118

Need Fine term type or more robot positions (delay time). Because the SE instruction is to close to the DO[401:dispe nsecomplete]. The Nordson may see both signals turn ON at the same time due to their scan rate.

42: !Move To Seal End, Turn Off Gun ; 43:L P[3] 1000mm/sec CNT100 SE ; 44: ; 45: !Move Clear of Nozzle ; 46:L P[4] 1000mm/sec FINE ; 47: ; 48: !Reset Coll Guard Sensitivity ; 49: COL GUARD ADJUST ; 50: ; 51: !Set Dispense Complete ; 52: DO[401:Disp1Complete]=ON ; 53: ; 54: !Wait for Dispense Vol. OK ; 55: WAIT DI[387:Dsp1VolumeOK]=ON ; 56: ; 57: !Reset Dispense Complete ; 58: DO[401:Disp1Complete]=OFF ; 59: ; 60: !Reset Disp Robot in Process ; 61: DO[393:Disp1RbtinPrc]=OFF ; 62: ; 63: !Post-processing for Disp Equip ; 64: !Insert Statements ; 65: ; 66: LBL[20] ; 67: ; 68: !Purge or Go To Dropoff ; 69: WAIT (DI[51:GoToDropoff1]=ON OR DI[95:PurgeGun1Req]=ON) ; 70: ; 71: !Check for Dropoff ; 72: IF DI[51:GoToDropoff1]=ON,JMP LBL[30] ; 73: ; 74: !MACRO - Purge Ped Gun 1 ; 75: CALL PRGPDGN1 ; 76: ; 77: JMP LBL[20] ; 78: ; 79: LBL[30:Dropoff] ; 80: ;

CUSW REL1.3

Process Application – Ped Stud (Macro) 1: 2: 3: 4: 5: 6: 7:L 8: 9: 10:L : 11:

!****************************** ; !MACRO PED STUD WELD; !****************************** ; ; !Move to Weld 1 ; !insert motion if necessary ; P[1] 1000mm/sec FINE ; ; !Select Schedule Weld 1 ; P[2] 100mm/sec FINE SPOT[S=1] ; ;

12: 13: 14:L 15: 16: 17:L : 18: 19: 20:L 21:

!Move to Weld 2 ; !insert motion if necessary ; P[3] 1000mm/sec FINE ; ; !Select Schedule Weld 2 ; P[4] 100mm/sec FINE SPOT[S=1] ; ; !Move Clear of Ped Welder ; P[5] 1000mm/sec FINE ; ;

Purge Ped Gun (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13:

!****************************** ; !MACRO PURGE PED GUN 1 ; !****************************** ; ; !Set Ext Purge 1 in Progress ; DO[97:ExtPurg1InProgrs]=ON ; ; !Pre-process Dispense Equipment ; !(insert statements) ; ; !Turn On Gun-Purge Schedule ; DO[416:Disp1Purge]=ON ; ;

14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25:

!Wait 'X' Seconds ; WAIT 7.00(sec) ; ; !Turn Off Gun ; DO[416:Disp1Purge]=OFF ; ; !Post-process Disp Equipment ; !(insert statements) ; ; !Reset Ext Purge 1 in Progress ; DO[97:ExtPurg1InProgrs]=OFF ; ;

Reset Stepper (Macro) 1: 2: 3: 4: 5: 6: 7:

!****************************** ; !MACRO RESET STEPPER ; !****************************** ; ; !Set Weld 1 Reset Stepper ; DO[590:W1ResetStepper]=ON ; ;

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!Wait for Stepper Reset ; WAIT DI[204:W1 SteppersReset]=ON ; ; !Reset Weld 1 Reset Stepper ; DO[590:W1ResetStepper]=OFF ; ;

Tip Burn In (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11:L : 12:

!****************************** ; !MACRO TIP BURN IN ; !****************************** ; ; !Reset Registers for Burn In ; R[14]=0 ; ; LBL[1] ; ; !Burn In ; P[1] 100mm/sec FINE SPOT[SD=1,P=1,S=62,ED=1] ; ;

13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24:

!Total Number of Burn Ins ; R[14]=R[14]+1 ; ; !Check Number of Burn-ins ; IF R[14]