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CCRW Robotics Training

Prateek Mishra
prateek.mishra@gm.com
11-5852-4763
11-8720-7576 (Cell)
Role of Robotics Engineer
Two Process Rule
Specifications
Standard I/O Definitions
Robot Program Structure
Sample Programs
User Manuals
Servo Guns
Outline
GM CONFIDENTIAL 2 9/17/2014
Robotics Engineers interface with Process, Design and
Execution engineers from BIW team as well as Controls
and Welding engineers from CCRW team for successful
execution of a project.

RESPONSIBILITIES:
Process Review and Follow Up
Project Estimating
Design Review and Follow Up
Robot ordering, tracking and delivery
Integration and launch activities
Role of Robotics Engineer
GM CONFIDENTIAL 3 9/17/2014
GM has specified the maximum number of processes on
one robot to be limited to 2. Process equipment is
defined as any peripheral device that the robot interacts
with.
Examples of two processes:
Dual pedestal spot welders welding independently
Carried spot welder and pedestal spot welder welding independently
Pedestal spot welder and pedestal dispenser
Pedestal spot welder and pedestal stud welder
Dual pedestal dispensers
Etc.

Material handling, Clinching, Roller hemming are NOT considered
as processes

Two Process Rule
GM CONFIDENTIAL 4 9/17/2014
First specifications were developed around
1997 to support the first common
architecture, commonly referred to as the
MPS-98 architecture.
Specifications formalize the equipment
requirements to our suppliers
Help in defining the dos and donts of the
equipment.
Standardize equipment used in body shops

Specifications
GM CONFIDENTIAL 5 9/17/2014
GRS1 Robot Technical Specification

GRS2 Robot Processing Specification

GRS3 Robot Integration Specification

GRS4 Series
PLC (GRS4-Section A)
Spot Weld (GRS4-Section B1)
Spot Weld Dense Pack (GRS4-Section B2)
Servo Gun (GRS4-Section B3)
Dispense Interface (GRS4-Section C)
Stud Weld Interface (GRS4-Section D)
MH Interface (GRS4-Section E)


Specifications
GM CONFIDENTIAL 6 9/17/2014
Latest specifications are available on the following link
http://supplier.body.gm.com/crw/production/main/globalStandards/roboticStandards.cfm
















ALWAYS CHECK THE WEB SITE FOR THE LATEST SPECIFICATIONS


Specifications
GM CONFIDENTIAL 7 9/17/2014
On robots
Digital inputs and ouputs1 - 65 are used for communication with
PLC.

Digital inputs and outputs greater than 65 are used for peripheral
devices.
For example:
DI[65] - DI[128] are used for communication with dispense
equipment number 1.
DI[129] - DI[192] are used for communication with dispense
equipment number 2.

Complete listing of I/O assignment is posted on Fanuc web
site has the latest generation of I/O assignment listing
Appendix_A_GM_G-RS4_I-O-02-07-08
Standard I/O Definitions
GM CONFIDENTIAL 8 9/17/2014
Robot programs are modular. This approach to
programming helps in reusing commonly used routines
and standardizing routines for example; Home_IO

Some routines are written in Karel and some are written
TP code.

Routines that interact with Fanuc core software are
typically written in karel.


Robot Program Structure
GM CONFIDENTIAL 9 9/17/2014

TP code is readable to the user in LS (Text) form on a
computer or on the robot teach pendent whereas karel
programs (.PC) are not readable. You have to have
source code .kl file to view the code and need a
complier to compile the .kl into a .pc file to load on a
teach pendent.

All robot path program start with a Style program

Robot Program Structure
GM CONFIDENTIAL 10 9/17/2014
BASIC CONCEPT OF PROGRAM STRUCTURE

Robot Program Structure
GM CONFIDENTIAL 11 9/17/2014
Main Style
Program
Pounce
Routine
Process
Routine
Move to Home
Routine
PLC
Initiate
Echo
Robot moves to
pounce position
At Pounce
OK to Continue
Robot moves into process
path and finishes path
Complete
(Optional)
Robot moves to
Home Position
At Home
OK to Continue
(Optional)
Reset all I/O
Robot Program Structure
GM CONFIDENTIAL 12 9/17/2014
PROG STYLE07
/ATTR
OWNER = MNEDITOR;
COMMENT = "GMT 966 STYLE 7";
1: !******************************** ;
2: !STYLE6 : GMT966 ;
3: !******************************** ;
4: !PROGRAM : GMT966 ;
5: !ASSEMBLY: Liftgate ;
6: !ROBOT ID: yd130_r01 ;
7: !******************************** ;
8: GO[2:ManualStyle]=7 ;
9: ECHO OPTION ;
10: MAINT_PROG=MOV_REPR ;
11: CALL POUNCE ;
12: CALL STPR_CHK ;
13: CALL S07PROC1 ;
14: RUN CAP_WEAR ;
15: MOVE TO HOME ;
16: WAIT (F[1:Capwear Complete]) ;
/POS
/END

/PROG S07PROC1
/ATTR
OWNER = MNEDITOR;
COMMENT = "GMT 966 WELD 1";
1: !******************************** ;
2: !PATH: s06proc1 ;
3: !******************************** ;
4: !PROGRAM : GMT966 ;
5: !ASSEMBLY: Liftgate ;
6: !ROBOT ID: yd130_r01 ;
7: !******************************** ;
8: !BEGIN PROCESS - PATH SEGMENT ;
9: SET SEGMENT(50) ;
10: UTOOL_NUM=1 ;
11:L P[11:w90100] 400mm/sec CNT100
: SPOT[SD=3,P=1,S=1,ED=13] ;
12:L P[12] 800mm/sec CNT75 ;
13:L P[17:w90103] 400mm/sec CNT100
: SPOT[SD=3,P=1,S=1,ED=13] ;
14:L P[18] 800mm/sec CNT75 ;
15:L P[19] 800mm/sec CNT50 ;
16:J P[20] 60% FINE ;
17: SET SEGMENT(62) ;
18:J P[21] 100% FINE ;
19: SET SEGMENT(63) ;
20:J P[22] 100% CNT100 ;
Every weld spot
SHOULD have a
weld spot number
Latest specifications are available on the following link
http://supplier.body.gm.com/crw/production/main/globalStandards/roboticStandards.cfm
















ALWAYS CHECK THE WEB SITE FOR THE LATEST SPECIFICATIONS


Users Manuals
GM CONFIDENTIAL 13 9/17/2014
Servo Guns are different from Air Guns in the following
manner

Pressure is controlled by the robot servo amplifier

Calibration of weld guns is different from air guns

Robot arm does the equalizing

Weld spots are programmed with the stationary tip touching the metal

UTOOL definition is critical for proper operation (RS2 standards have to be
followed)

REFER Customization Servo Gun Manual from the web site for more details
Servo Guns
GM CONFIDENTIAL 14 9/17/2014

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