Fanuc Robots With Device Net: JDS402 - Robot Programming

Fanuc Robots with Device Net
JDS402 – Robot Programming
JDS402 Robot Programming 1 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Table of Contents
Page Description
3. 1K Systems overview
12. 1K System Dispense Head Checking Procedure
13. 1R Systems
15. Trouble Shooting
18. Dispensing Methods
21. Nozzle Selecting
24. Temperature conditioning
25. Device Net
29. Configuring the robot I/O
33. GM RS4 I/O Map
37. Automatic Sequence of Events I/O
40. Robot Programming TCPP
43. Motion Planning
45. Dispenser I/O
46. Tuning the Dispenser
47. Seal Schedules
50. Disperser Setup
52. Equipment Delay
54. Gun On-Off Delay
55. Running the Dispense Path
56. Payload

1K Systems Overview
The 1K systems use a shot meter as a metering device. The shot

meter works by using displacement as a method of dispensing
material.
The faster and harder the piston rod is moved into the material
vessel, the more that the material pressure will increase causing
the material to flow faster out of the material outlet port.
Piston Rod
Material Vessel
Outlet Port

1K Systems Overview
Main Components:
Linear Transducer
MLDT
Electrical Connector
Air Servo Valve
Air Cylinder
Solenoid Valves
Piston Rod
Seal Cartridge
PSI Transducer
Refill Valve (behind
material hose block)
Material Vessel
Dispense Valve

1K Systems Overview
Devices and what they do:
Linear Transducer:
Tells the system how
much material has Air Servo Valve: Controls
been dispensed. the up and down direction
of the air cylinder.
Refill Solenoid Valve:
When energized opens Dispense Solenoid Valve:
the refill valve. When energized opens the
dispense valve.
Piston Rod:
Used to displace the Seal Cartridge: Has three
material in the seals and a scraper to
dispense chamber. prevent material from
leaking out from the
Refill Valve: material chamber.
Uses air to operate.
When open connects Pressure Transducer:
the pump pressure to Used to tell the PC how
the material used in much pressure is in the
refilling the material dispense chamber.
chamber.
Dispense Valve:
Uses air to operate.
When open allows the
material to flow out of
the Dispense chamber.

1K Systems Overview
MLDT
Magnetostrictive Linear
Displacement Transducer
Voltage Range 0-10vdc Voltage

Voltage
fully
@home
System Operation dispensed
below 1
is
voltabove
At the start of the cycle the PC 9vdc
takes a voltage reading (style
strobe) and then the system
dispenses. The piston
rod/magnet moves down – the
voltage increases and when
the robot sends the Dispense
complete signal another
voltage reading is taken. The
first voltage is subtracted from
the second voltage. Then it is
multiplied by a kfactor to equal
volume dispensed in CC.

1K Systems Overview
Trim adjustment screw
Pressure Transducer:
The pressure transducer tells the 1K system
how much pressure is in the dispense chamber.
It is designed so that it is flush mount. This
prevents material from packing around it and
giving inaccurate readings. The range of the
transducer is 0-5000 PSI with a 1-10VDC
output. 0psi = 1VDC.
To check the pressure transducer use the
following formula.
(Pressure x .0018) +1 = Voltage
Example: 700psi x .0018 +1 = 2.26v
The Transducer has a new feature of an trim

pot. To adjust, remove the screw cover on the
zero trim adjustment and turn the trim screw
until the voltage equals 1vdc with zero PSI on
the pressure transducer. Replace the trim screw
cover.

1K Systems Overview
Servo
Valve
Air Servo Valve:

When the system is not in a dispense mode
(Gun Off) the Servo signal will be at 5V. At 5v
the same pressure should appear on both sides
of the Air Cylinder (within 15 PSI of each other)
preventing the piston from moving. Pressure
Transducer
Above 5v, the material pressure increases by
having more down pressure and exhausting the
pressure below the piston.
Below 5v, The air pressure under the piston
increases and decreases air pressure above the
piston. This will send the piston up (home
position). Material force on the piston rod also
helps to send the rod up.
NOTE: The Servo signal does NOT reflect the
incoming robot flow command.

1K Systems Overview
Servo
Valve
Pressure Loop:
If the robot velocity increases, the output is above 5V
when the pressure transducer feedback is subtracted
from it. A signal higher than 5V causes the Servo
Valve to send maximum pressure to the top of the air
cylinder and exhaust the bottom of the air cylinder.
The material pressure will increase. Pressure
Transducer
When the material pressure increases to where it is
the same as the robot velocity input, the output to the
Servo Valve is 5V at idle.
If the robot velocity decreases, the output is below 5V
when the pressure feedback is subtracted from it. A
signal lower than 5V causes the Servo Valve send
maximum pressure to the bottom of the air cylinder
and exhaust the top of the air cylinder, and material
pressure decreases.
When the material pressure decreases to where it is
the same as the robot velocity, the output to the Servo
Valve is 5V at idle.
1K Systems Overview
Servo
Valve
The Robot Flow Command signal will change the

pressure in the dispense head. The range of the Pressure
robot flow command signal is from 0-4095. The Transducer
pressure capability of the dispense head is
2240 PSI = Ratio x Air pressure (16 x 140psi).
1R
80 psi
1K
System
Psi 60
40
20

1K Systems Overview
1K Dispense Head Sequence of Operation

Manual Mode:
1. The Refill button is depressed and the PC goes into
a refill mode.
2. The Refill Solenoid valve is energized and the Refill
Valve opens. Pump pressure forces material into
the material chamber. The dispense rod starts
going in the up direction. The air servo is controlling
the pressure in the material chamber to 200 PSI.
When the MLDT voltage is less that 1 volt the Refill
Solenoid de-energized and the Refill Valve closes.
The air servo continues to raise the piston rod to a
predetermined position, relieving the pressure in the
material chamber.
2. The higher the pump pressure is the faster the
dispense head will refill.
3. The Manual Dispense button is depressed and the
PC goes into a dispense mode.
4. A voltage reading is taken of the MLDT position.
5. A command voltage is sent to the servo valve
driving it in the down direction and the dispense
solenoid valve is energized and the dispense valve
is opened.
6. The command voltage uses feedback from the
pressure transducer to determine how much
voltage/ force needs to be generated so that the
voltage vs. pressure match. The piston rod travels
down.
7. After dispensing the Refill button is depressed and
the voltage reading is taken of the MLDT and the cc
per dispense is calculated. Then step 2 is repeated.

1K Systems Overview
1K Dispense Head checking procedure:
This Procedure test the Dispense valve, Refill

valve, MLDT, Servo Valve and Pressure
Transducer.
1. On the Production screen put the
system into the manual mode. By
pressing to Manual Auto button until the
Manual dispense button appears. Press
the Refill button and verify that NO
material is coming out of the dispense
valve – if it is replace the valve.
2. Depress the Manual Dispense button
until the dispense head has fully
depleted all of the material.
3. Continue holding the Dispense button in
for 15 seconds. If the pressure on the
gauge is within + or - 150 psi of zero the
pressure transducer is calibrated. If not
replace or calibrate the transducer
4. Let go of the button and wait for another
15 seconds. If the gauge starts to
increase the refill valve could be leaking.
Replace the refill valve if the pressure
starts to increase.
5. Depress the Refill/Reset button. The
head should refill without a fault. If it
faults increase the pump pressure or
refill time.
6. After refilling the servo output voltage
will be 5 volts. Both of the air cylinder
pressure gauges should be within 15 psi
if not replace the servo valve.
7. If there was not a volume displayed and
the piston rod did not move check the
MLDT.

1R Systems Overview
The Autostream 1R system includes a proportional

material regulator as a pressure control device. The
output pressure of this pneumatically operated valve is
adjusted by changing the control air pressure applied to
it. The changes can be achieved by manual adjustment
of the air pressure, or by changing the strength of the
electronic flow rate signal
( 0 to 10v DC or 0 to 4095 Dnet ). The 1R system can
dispense from 5cc to 55 gallons of material in one job.
The Pump station Consists of a single or dual

(automatic crossover) pump that supplies the material
to the 1R Material regulator
The Flow monitor measures the material volume for

each job. The volume is calculated and matched to a
body style table to determine if the correct amount of
material was put on the job – if not a fault will occur
stopping production.
The Proportional Material Regulator uses the incoming

(pump) pressure as a base to regulate the output
pressure. Air pressure is used to control the outlet
pressure.
Examples:
Material Inlet Air PSI = Outlet PSI
2000 PSI 50 PSI 1000 PSI

3000 PSI 0 PSI 0 PSI
3000 PSI 25 PSI 750 PSI
3000 PSI 50 PSI 1500 PSI
3000 PSI 75 PSI 2250 PSI
4000 PSI 50 PSI 2000 PSI
A transition block or dispense (traced) hose is used to supply regulated material
to the dispense valve. Systems using a transition block are called closed
coupled and have a quicker reaction time then system using a hose.
The dispense valve is pneumatically controlled by a 24vdc spring return solenoid valve. If the
valve is energized the valve is opened. If the Gun On signal goes low (de-energized) the
solenoid valve will spring return and the dispense valve will close.

1R Systems Overview
The Proportional Material Regulator uses

Air Servo
an air servo regulator to convert the Regulator
electrical command signal (0 to 10vdc) to
an air pressure. The servo regulator
pressure range is 0 to 10vdc and 0 to 80
PSI.
Example
Flow Voltage Air
Command Pressure Air Pressure
Gauge
0 0v 0 PSI
1024 2.5v 20 PSI
2047 5v 40 PSI
3071 7.5v 60 PSI
4095 10v 80 PSI
The air servo regulator is the interface

between the electrical signals and the
mechanical or outlet pressure of the
valves.
The Material has three gauges that are

very handy in trouble-shooting.
1. Air pressure gauge Material Material
2. Material inlet pressure gauge Outlet Inlet
(pump) Gauge Gauge
3. Material outlet pressure gauge
(dispense valve)
The regulator runs best when setup to run in the mid range. There should be 500 to
1000 PSI more pressure on the inlet gauge than the outlet gauge when the system is
dispensing. To adjust for this several factors come in effect – Pump Pressure –
Temperature – Nozzle size – Robot speed. The regulator can be purchased with
three different size valve seat combinations. “A” .281in. - “B” .312in. – “C” .375in.
The housing are stamped with an A, B or C to identify them. The A size is normally
used for small beads and the C version is used with very thick viscosities and large
beads.

1R & 1K Fault Recovery
If a fault is on it will be shown with a

red light. The setup screen
determines if the fault is a Major or
Minor
Note this picture shows 4 faults 3
Major and 1 Minor.
This a record of the faults that has a

date/time log. The most recent fault
has a red dot next to it.
Fault Problem Solution

1R & 1K Low Volume 1. Plugged tip 1. Replace tip and Purge.
Visually Verified not enough 2. Expired Material 2, Change Material and Purge
material. 3. Low Dispense Pressures. 3, Check operation of Dispense head.
4. Plugged Material Filter. 4. Change Material Filter Element.
5. Pump Pressure to Low 5. Reset Pump PSI to Specifications.
6. Plug in material path 6. Use pressure gauges to locate
pressure drop in system.
7. Material not at temperature 7. Check Temperature system.
1K only 8. Air Intensifier not working. 8. Check operation of Intensifier tank
PSI= 150 Outlet =140 PSI
9. Scaling or Compensation out 9. Reset Scaling or Batch
of range. Compensation.
10. Body ID target changed. 10. Reset Body ID Target.
11. Flow monitor not working. 11. Replace Flow Monitor.
12. Dispense head not working 12. Check operation of dispense head
(regulator or Shotmeter). (Plugged Regulator or Seized
shotmeter) check solenoid valves
13, Robot Command signals to 13. Check Robot Varibales.
Low.
1R & 1K Low Volume 1. 1K - MLDT Linear transducer 1. Replace MLDT and check wiring.
Visually Verified Good Bead not functioning correctly
2. 1R – Flow Monitor or sensor 2, Check Flow Sensor, Monitor and
not working. check wiring.
3. 1R- Flow Monitor K factor not 3, Reset the Flow Monitor K factor in
set correctly the set up screen.


1R & 1K High Volume 1. Worn or not tip 1. Replace tip and Purge.
Visually Verified too much 2. Material too thin 2, Change Material and Purge
material 3. Pump pressure to high 3, Check and reset pump pressure
4. Material temperature to High. 4. Check Temperature system and
reset the material temperature.
5. Global Scaling or Batch 5. Reset Scaling and Batch
compensation to high. compensation to 1.
6. Robot Command Voltage to 6. Reset Variables in robot controller.
High
7. Body ID target value 7. Reset body ID target value.
inaccurate.
1R only 8. Regulator Seat passing 8. Replace Material Regulator.
1K only 9. Refill Valve passing. 9. Replace refill valve or Solenoid
valve.
1R & 1K High Volume 1. Worn or not tip 1. Replace tip and Purge.
Visually Verified Good Bead 2. Material too thin 2, Change Material and Purge
3. Pump pressure to high 3, Check and reset pump pressure
4. Material temperature to High. 4. Check Temperature system and
reset the material temperature.
5. Global Scaling or Batch 5. Reset Scaling and Batch
compensation to high. compensation to 1.
6. Robot Command Voltage to 6. Reset Variables in robot controller.
High or speed to slow.
7. Body ID target value 7. Reset body ID target value.
inaccurate.
Refill Fault 1K only 1. Plugged material filters 1. Change Material Filters
2, Air pressure not on. 2. Turn on Air pressure to dispense
head.
3. Pump Pressure to low. 3. Check pump PSI and reset to
specifications.
3. Temperature system not on 4. Start temp system and wait for
and up to temp. pumps to pressurize.
5. Refill Solenoid/Valve not 5. Replace Refill Solenoid Valve.
working.
6. Pressure transducer not 6. Replace pressure transducer.
reading.
7. MLDT not working 7. Replace MLDT.
8. Dispense head seized. 8. Replace dispense head.
9. Refill time set to short. 9. Reset the Refill time in the setup
screen.
Network Error 1. Communication has stopped 1. Check for 24V at the device net
between the robot and terminals and reset robot
NOTE: Robot Controller must Autostream system controller and Autostream
be on before starting panel.
Autostream controller.. 2. Controller/Robot locked up. 2. Reboot robot then Autostream
Controller.
3. Device net card not working 3. Replace device net card.


I/O Error 1, One of the device net nodes 1. Look at the I/O device screen to
is not working see if all of the nodes are
Autostream Panel Error correctly. operating. Press fault reset button
to clear.
2. Cable or wiring disconnected 2. Check for 24VDC and nodes and
check the cables, tees and
terminators.
3. Node not reading correctly. 3. Reboot system if not working
Does not have 3 green lights. replace buss coupler.
No Material Dispensed 1. The robot did not send the 1. Autostream software is operating
NO Fault Robot Style bit and the correctly. The robot needs
Job was Ignored. to send the robot Style bit.

Types of Dispensing
Dispensing Methods
Ingersoll-Rand
specializes in
delivering effective
solutions for high
viscosity industrial
Adhesive, Sealing,
and Lubrication
Applications.
Through the
years, Ingersoll-
Rand has
developed
solutions for a
wide variety of
applications and
has refined them
into a flexible and
innovative
collection of
processes.

Types of Dispensing
Dispensing Methods
Applications:
Ingersoll-Rand Systems expertise crosses industrial and international boundaries
to provide the highest levels of technology and reliability to customers who have a
desire to improve value throughout the life of their product.
Hem Adhesive Bead

Joint Sealer
Adheres joints where the
Penetrates and seals a
workpiece is crimped
(hemmed) over the adjoining joint
piece
Hem Adhesive Ribbon Shaped Bead

Provides a low, wide profile Beads are shaped for
when the workpiece is gasketing, workpiece
dimensionally inconsistent inconsistency, or vibration
dampening as well as for
special applications
Lap Joint Adhesive Bead

Adheres joints where the
metal is welded or simply Patches and Coatings
held in place by the adhesive Sprayed patches can replace
hand applied patches in Body
Panel Reinforcement, Sound
Deadening, and
Lap Joint Adhesive Ribbon Weatherproofing
Provides a low, wide profile
when the workpiece is
dimensionally inconsistent
After Hem Sealer

Seals a joint that has been
crimped (hemmed) over

Types of Dispensing
Dispensing Methods
Processes
Ingersoll-Rand Systems utilizes award winning technology and state-of-the-art
controls to provide the most effective and reliable processes available.
Streaming
Material is applied to the workpiece
by a thin jet so that the process is
not affected by inconsistencies in
the workpiece
Extrusion String Dispersion

Material is deposited onto the Provides a wide
workpiece directly where bead application pattern
shape is critical to its performance without atomizing
the material
Spraying
Airless application of materials in
a wide pattern of consistent
thickness
Clip Fan (Precision) Spraying

Application of materials in a
pattern of tightly controlled width

Types of Nozzles
Dispensing
Nozzles
Ingersoll-Rand uses a wide variety of nozzles to dispense a array of different
materials in different applications. Specialty nozzles can be made.
Shown are String dispersion, tip orientation, specialty, extrusion

Horse hair brushes and robotic teach tips
Cone tip streaming, HV style streaming, spraying tips.

Types of Nozzles
Dispensing
Streaming vs Extruding
Streaming involves faster robot speeds (500-1500mm/s)
and higher pressures the extruding. The dispense system
creates a pressure behind a small orifice. The material is
forced out of the nozzle in the form of a small stream. The
larger the nozzle the less force the stream has and the
closer the nozzle needs to be programmed to the part.
Streaming can works if the work piece is horizontal, vertical
or overhead. Streaming is the preferred method of
dispensing.
Extruding Nozzle Selection

When using a extruding nozzle the bead size in normally larger (10mm)
then streaming. To create a 10-20mm bead with a streaming tip it would
take slow robot speeds and very high pressures. With the extruding nozzle
the robot speeds can increase, but the bead can only be dispensed in a
horizontal (down) direction. There are many ways to misuse an extrude
nozzle so we will use the following statement as our guide. The diameter
of the opening of the nozzle is equal to the diameter of the bead that you
want to apply.

Types of Nozzles
Dispensing
Adaptors
Sometimes it is necessary to install an angle offset adaptor to
help make the programming easier. All of the angle adaptors
have tip orientations so that they can be installed on the
dispense valve in 90 deg. Rotations.
Adaptors can only be install on special dispense valves
Such as a 105B038D dispense valve or a 105B038xD 4 or 6
inch extended dispense valve.
403-114-30 403-114-45A
403-114A 403-114-90B
COLLARS
400-667
400-667A 403-132 403-043
3/4 in. x 16 thd. .550
3/4 in. x 16 thd. .494 opening 3/4 in. x 16 thd. .191 opening 7/8 in. x 14 thd. .500 opening
opening
Used with Standard Spray Tips Used with HV Type Spray Tips Used with Orientated Spray
Used with Extrusion Nozzles
Tips.

Types of Temperature
Dispensing Conditioning
Temperature
Temperature conditioning is used to create a stable environment so that the
viscosity of a material remains constant throughout the day. This will improve
the job to job quality of a bead. Temperature can be used to make a high
viscosity material dispensable without using excessive pump pressure. Some
materials can adhere to a oily panel better if the temperature is elevated.
Ingersoll-Rand uses water as a medium to condition the material. A closed loop
system pumps water through the dispense valve (point of application), dispense
head, conditioned hoses and header. The system has an electric heater and a
chiller to condition the water. A RTD resistive thermal detector is used to
measure the material as close to the nozzle as possible. The RTD feeds back
to the PC which in turn controls the temperature of the water.
60 deg. F
70 deg. F
80 deg. F
This example show the difference temperature can make. The

dispense pressure and robot speed is the same only the
temperature has been changed.
Shown is the PC
temperature window
which can be
displayed in Celsius
or Fahrenheit
The 100 ohm
platinum bulb RTD

Inputs/
Outputs Device Net
Device Net
Ingersoll-Rand use device net as a way of communicating from the robot to the
PC – The robot is the master and the PC is the slave. Also the communication
from the PC to the Robot / Pedestal mount Junction box is device net – PC is
the master and the J-box nodes are the slaves. Device net uses a 5 wire
connector that contains a 24vdc power, a high – low CAN signal and a shield
(similar to a PLC cable). The cables are all shielded twisted pair wiring that
resists noise. The PC has communication cards installed – one for each
network. The communication between the robot and the PC is configured to
have 64 inputs and 64 outputs.
SLOT 3
SLOT 2
SLOT 1
Jumper Settings
364-207 Device Net Communications

Card (DNP)
The dip switches set the address to

match correct card to the equipment in
the PC software. If a card is removed
the DIP SWITCHES must be set.
NOTE: IF the PC is started up without EQUIPMENT 1

MAC ID 10
24vcd power on communications the 500 K BAUD
device net software will not load and the
PC screen will show a device net error. EQUIPMENT 2
MAC ID 12
500 K BAUD

Inputs/
Outputs Device Net
PC Nodes
The PC uses several nodes to send inputs and outputs. The main control cabinet, each
dispense J-box and pump J-box will have a node. The node consists of a buss coupler,
which communicates with the controller card. Attached to the buss coupler an array of I/O
cards can be attached to it. Examples are 24vdc Input – 24vdc Output – Analog Input 0-
10vdc – Analog Output 0-10vdc.
Node Addressing in the Wago Blocks

DeviceNet recognizes each Wago Block by its Node Address. Every device on a DeviceNet
network must have a unique (different) Node Address.
DeviceNet’s communication speed is determined by its Baud Rate. Every device on a
DeviceNet network must be set at the same Baud Rate. The Dispenser baud Rate should
be set to 250 baud.
Node Addresses and Baud Rates are set by DIP (Digital Input) Switch on the Wago Blocks.
Analog Output Card

Analog Input Card
Input Card
Output Card
Buss Coupler
Fuses
Baud Rate on Autostream Devices is

ALWAYS 250k. This setting should not
change
24 = 16
25 = 32
20 = 1
21 = 2
22 = 4
23 = 8
DIP
SWITCHES
This picture shows a dispense J-box node.
The Node Addresses is the sum of the switches that are turned “ON”. Address #1 is shown.
Address #3 would have switches 1 & 2 “ON” since 1 + 2 = 3
Address #13 would have switches 1, 3, & 4 “ON” since 1 + 4 + 8 = 13

Inputs/
Outputs Device Net
Device Net Card Identification and Settings
Jumper
Settings
364-207 Device Net Communications Card (DNP)
No Jumper Settings
363-871 PCI Device Net Communication Card
Jumper Setting
363-459 Device Net

Communication Card (DN)

Inputs/
Outputs Device Net
Physical DeviceNet Layout

Each DeviceNet network (bus) must be set up as a “single-file” string of devices (trunk)
connected by special DeviceNet cable.
Each DeviceNet network must have terminating resistors (Terminators) at each end.
Devices are dropped off the trunk by Tees and smaller cables (branches).
DeviceNet cable is available in Thick and Thin. Maximum trunk (bus) length for Johnstone
equipment is 250m for Thick cable and 100m for Thin cable. Johnstone uses Thin cable as a
standard because it is much more flexible and compact than Thick.
Maximum branch length for Johnstone is 6m. Johnstone equipment is always attached to the
trunk line, so this constraint does not matter.
Terminator Cable Tee
Tee
Cable
Terminator
Dispenser Temperature Pump System

Node #1 Conditioner/ Node #3
main control
panel
Node #20

Inputs/ Configuring
Outputs The Robot I/O
Device Net Variables to PC

These Values should be entered so that the Robot can talk to the PC.
Communication Setup (Menu/I-O/TYPE{F1}/0{next page}/DEVICE NET
Rack 81 = PLC Controller Rack 82 = Ingersoll-Rand PC
In rack 82 board the detail values are:

Mac ID: GM Equipment #1 = 10 Equipment #2 = 12 At 500 Baud
CAMI Equipment #1 = 20 Equipment #2 = 22 At 500 Baud
Daimler Chrysler Equipment #1 = 15 Equipment #2 = 16 At 125 Baud
Baud Rate = 500K or 125K for Daimler Chrysler specs

Board auto restart = ON
Input resume state = LAST
Size of output from master = 0
Size of input from master = 0
Setting the Device net I/O assignment:

1 Device name = Ingersoll-Rand 2 Comment = PC
3 Vendor ID = 8
4 Device Type = 12
5 Product code = 0
6 Polled I/O = default yes
Digital input = 64
Digital output = 64
Analog input = 0
Analog output = 0
Strobed = default no
Rest of the values are no or 0
Under the Rack 82 the Ingersoll-Rand definitions are added.

Device name = Ingersoll-Rand (device created above)
A dual system will have 2 Mac ID’s set up.
After the I/O have been set up the robot need to reboot and the device networks
need to be put online

Inputs/ Configuring
Fanuc Information
3. DeviceNet Board Setup and Configuration
3.1. Configuring and Connecting the DeviceNet Interface Daughterboards
Before you can connect the DeviceNet Interface daughterboards to devices on the DeviceNet network, you must
configure them properly. Use Procedure 3.1. to configure the daughterboards.
When you configure DeviceNet Interface daughterboards, you use two screens: the I/O DeviceNet Board List
screen and the I/O DeviceNet Board Detail screen. Refer to Table 3.1. and Table 3.2. for a listing and description of
each of the items on these screens.
Table 3.1. DeviceNet Board List Screen Items
DESCRIPTION
ITEM
Board This is the number of the DeviceNet Interface daughterboard, 1-4.
Comment This is text you enter to describe the daughterboard. A comment is not required.
This is the I/O rack that will be used to configure the I/O used with the daughterboard on the
controller. DeviceNet Interface daughterboards must use racks 81 through 84:
Rack 81 - Daughterboard 1
•
Rack Rack 82 - Daughterboard 2

•
•
•
You cannot change the rack number of a daughterboard.
This is the current state of the DeviceNet Interface daughterboard.

ONLINE indicates the board is presently active. Information to and from devices configured on this
•
network is being updated.

Status OFFLINE indicates that no data is being transferred to or from devices connected to the board.
•
Scanning of devices connected to this board will not start at power up.
ERROR indicates that an error has been detected. The board is effectively off-line, but scanning will
•
be attempted after power up.

Inputs/ Configuring
Table 3.2. DeviceNet Board Detail Screen Items
ITEM DESCRIPTION
Board This displays the number of the selected daughterboard.
Status This displays the status of the selected daughterboard: ONLINE, OFFLINE, ERROR.
The model of scanner represented by this daughterboard. Currently two kinds are
Scanner Type
supported: SST 5136-DN and SST 5136-DNP.
The type of motherboard used with the daughterboard. Currently there are two kinds:
Motherboard
"full-slot" and "wide-mini."
This is the Media Access Control ID used by the daughterboard. It must have a value
MAC-Id of from 0 to 63. The MAC-Id must be different from the MAC-Ids of all other devices
on the network.
This specifies the data rate used in transfers between the DeviceNet Interface board
and the devices on the network. Specify one of the following baud rates:
Baud Rate 125 KB
•
250 KB
•
500 KB
•
When this is set to ON, the board will automatically restart communication with the
DeviceNet network after a board or network error has occurred and the error situation
Board Auto-restart
has been resolved. Setting this value to OFF turns off board auto-restart. The default
value is OFF.
The two valid values for this setting are LAST and ZERO, and this setting affects all
input I/O ports (digital, analog, group, and so forth) which have an assigned rack
value equal to the board's rack number. When the input resume state is set to LAST,
Input resume state
these input ports will retain their last known values if the port goes offline. When the
input resume state is set to ZERO, the port values are set to zero. The default value
is LAST.
Slave status indicates the status of the slave connection of this DeviceNet board. If
the slave connection is not enabled (if size of output from master and size of input to
Slave Status master are 0), this field displays OFFLINE. If it is enabled and the remote master has
not yet connected, this field indicates IDLE and error DNET-125 is posted. If the
remote master is connected, this field displays ONLINE. This field is display only.
This sets the error severity level of the error DNET-125 that indicates the slave
Slave Error Severity
connection is idle. Select WARN, STOP or PAUSE as required.
For slave operation, in which the R-J3iB controller acts as a slave to an external
Slave Operation: Size
master, this specifies the size of the output from the master to the daughterboard, in
of output from master
bytes. See Figure 3.1..
For slave operation, in which the R-J3iB controller acts a slave to an external master,
Slave Operation: Size
this specifies the size of the input to the master from the daughterboard, in bytes.
of input to master
See Figure 3.1..

Inputs/ Configuring
Procedure 3.1. Configuring and Connecting DeviceNet Interface Daughterboards

1.Press MENUS.
2.Select I/O.
3.Press F1, [TYPE].
4.Select DeviceNet. You will see a screen similar to the following.
Board List 1/4

Board Comment Rack Status
1 [ ] 81 OFFLINE
2 [ Ingersoll] 82 OFFLINE
3 [ ] 83 OFFLINE
4 [ ] 84 OFFLINE
1.To configure each daughterboard, move the cursor to the daughterboard you want to configure and
press F4, DETAIL. You will see a screen similar to the following.
Board Detai
lBoard: 1 Status: OFFLINE
Scanner type:
SST 5136-DN-104
Motherboard: Full-slot
1 MAC-ID: 0
2 Baud-rate: 500 KB
3 Board auto-restart: ON
4 Input resume state (rack 82): LAST
5 SLAVE Error Severity: WARN
6 Size of output from master: 0 Bytes
7 Size of input to master: 0 bytes
1.Move the cursor to MAC-Id and type the MAC-Id. This must be a value from 0 to 63 and must be different
from the MAC-Id of any other device in the network. (choose 0)
2.Move the cursor to Baud-rate, and press the function key that corresponds to the baud rate you want to use:
For 125 KB, press F2.
o

o

o
3.Move the cursor to Board auto-restart to set the board auto-restart state:
To turn it on, press F2.
o
4.Move the cursor to input resume state to set the input resume state for the board:
If inputs are to retain their last state, press F2.
o

Inputs/ Configuring
GM RS4 I/O: Dispense controller digital inputs (Channel 82 node 10 / 12)
Robot input Description Signal name Node address

E1 / E2
In 65 / 129 Dispense #/ Ready diSL#Ready N10 / 12: I01
In 66 / 130 Dispense # In Process diSL#InProcess N10 / 12: I02
In 67 / 131 Dispense # Volume OK diSL#VolumeOK N10 / 12: I03
In 68 / 132 Dispense # Major Fault DiSL#MajorFault N10 / 12: I04
In 69 / 133 Dispense # Minor Fault diSL#MinorFault N10 / 12: I05
In 70 / 134 Dispense # Remote Start In Progress diSL3RmtStartInp N10 / 12: I06
In 71 / 135 Dispense # Automatic Mode diSL#AutoMode N10 / 12: I07
In 72 / 136 Dispense # Manual Mode diSL#ManMode N10 / 12: I08
In 73 / 137 Dispense # De-Pressurized diSL#DePrsized N10 / 12: I09
In 74 / 138 Dispense # Drum Empty diSL#DrumEmpty N10 / 12: I10
In 75 / 139 Dispense # Flow Meter bypassed diSLMBypassed N10 / 12: I11
In 76 / 140 (Reserved) (Reserved) N10 / 12: I12
In 77 / 141 Dispense # meter Full diSL#MeterFull N10 / 12: I13
In 78 / 142 Dispense # meter Empty diSL#MeterEmpty N10 / 12: I14
In 79 / 143 Dispense # meter Pressurized diSL#MeterPrsized N10 / 12: I15
In 80 / 144 Dispense # meter Near Empty diSL#MeterNrEmty N10 / 12: I16
In 82 / 146 Dispense # Felt Advanced diSL#FeltAdvanced N10 / 12: I18
In 83 / 147 Dispense # Primer Check Passed diSL#PrimeChkPass N10 / 12: I19
In 84 / 148 Dispense 1 Primer Check Failed diSL#PrimeChkFail N10 / 12: I20
In 85 / 149 Change Primer Brush diSL#ChangePBrush N10 / 12: I21
In 88 / 152 Dispense # Purge Request diSL#PurgeReq N10 / 12: I24
In 89 / 153 Dispense 1 Purge in Process diSL#PurgeInProcess N10 / 12: I25
In 91 / 155 Volume # Dispensed Data Bit 1 diSL#VolDatBit1 N10 / 12: I27
In 104 / 168 Dispense # Fault Data Bit 1 diSL#FaultBit1 N10 / 12: I40
In 105 / 169 Dispense # Fault Data Bit 2 diSL3FaultBit2 N10 / 12: I41
In 112 / 176 (Reserved) (Reserved) N10 / 12 : I48
In 113 / 177 Dispense # Ejection Valve(s) Ready DiSL#EjValveRdy N10 / 12: I49

Inputs/ Configuring
GM RS4 I/O: Dispense controller digital inputs (Channel 82 node 10 / 12)

continued:
Robot Input Description Signal Name Node Address
E1 / E2
In 118 / 182 Dispense # Ejection Complete diSL#EjectCmpl N10 / 12: I54

Inputs/ Configuring
GM RS4 I/O: Dispense controller digital outputs (Channel 82 node 10 / 12)
Robot Output Description Signal Name Node Address
E1 / E2
Out 65 / 129 Dispense # Style Bit 1 doSL#StyleBit1 N10 / 12: O01
Out 73 / 137 Dispense # Robot in Style doSL#RbInStyle N10 / 12: O09
Out 74 / 138 Dispense # Style Strobe doSL#StyleStrobe N10 / 12: O10
Out 75 / 139 Dispense # Gun 1 On doSL#Gun1On N10 / 12: O11
Out 80 / 144 (Reserved) (Reserved) N10 / 12: O16
Out 81 / 145 Dispense # Dispense Complete doSL#DispenseCmplt N10 / 12: O17
Out 82 / 146 Dispense # Remote Start doSL#RemoteStart N10 / 12: O18
Out 84 / 148 Dispense # Pre-Pressure meter doSL#PrePressure N10 / 12: O20
Out 85 / 149 Dispense # Reload meter doSL#ReloadMeter N10 / 12: O21
Out 86 / 150 Dispense # De-pressure meter doSL#DepressMeter N10 / 12: O22
Out 88 / 152 Dispense # Clear Primer Complete doSL#ClrPrimerCmplt N10 / 12: O24
Out 89 / 153 Dispense # Black Primer Complete doSL#BlckPrimerCmplt N10 / 12: O25
Out 90 / 154 Dispense # Urethane Complete doSL#UrethaneCmplt N10 / 12: O26
Out 92 / 156 Dispense # Advance Felt doSL#AdvanceFelt N10 / 12: O28
Out 93 / 157 Dispense # Waiting for Primer Data doSL#WaitPrimer N10 / 12: O29
Out 94 / 158 Dispense # Primer Brush Change Compete doSL#PrimerBrChCmplt N10 / 12: O30
Out 96 / 160 Dispense # OK to Purge doSL#OKToPurge N10 / 12: O32
Out 97 / 161 Dispense # Material Flow Command Bit 1 aoSL#MatFlowBit1 N10 / 12: O33
Out 98 / 162 Dispense # Material Flow Command Bit 2 aoSL3MatFlowBit2 N10 / 12: O34
Out 107 / 171 Dispense 1 Material Flow Command Bit 11 aoSL#MatFlowBit11 N10 / 12: O43
Out 108 / 172 Dispense 1 Material Flow Command Bit 12 aoSL#MatFlowBit12 N10 / 12: O44
Out 113 / 177 Dispense # Bead Shaping Command (bit 1) aoSL#BeadShp (Bit 1) N10 / 12: O49

Inputs/ Configuring
GM RS4 I/O: Dispense controller digital outputs (Channel 82 node 10 / 12)

continued:
Robot Output Description Signal Name Node Address

E1 / E2
The Analog Values are set up as a Group BCDB bit.

Menu/ IO/Group
The style bits are set up using a six group selection
The Analog bits are set up using a 12 group selection
Fanuc new software will have this set up for you.
Create a group from the Digital outputs rack 82 Mack ID 20 or 22 starting point N:33
for 12 Nodes
Reference range 0-4096 where 10V is equal to 4095 Style bits are set up as a
group BDCB bit .
The Body Styles are set up as a Group BCDB bit.
Create a group from the Digital Output Rack 82 Mack ID 20 or 22 Starting Point N:1
for 8 Nodes
Range is 0-255 different style bits

Inputs/ Automatic
Outputs Sequence
Robot Automatic Sequence of Operations:
1. PC Sends Signal IN PROCESS off

This signal verifies that the dispense head has been reset from the last job
(refilled) and is not in a purge mode.
2. PC to Robot - No Dispense Fault (Major)- Dispense Ready High – Do not look at

Volume OK condition at the beginning of a job, this bit can be low or high
depending if the last job was good or bad.
3. Robot Sends Body Style 1-255 (0 body style is a purge routine –NO Volume
Limits). Sent as a 8 bit Group Output. The style can be put into the program two
ways.
a. The style bit can be inserted in the path program.
b. The style bit can be inserted in the DETAILS of a JOB in the PART ID if
the job is configured for the disperser to be true. A separate job
is required for each body style and the style strobe is automatically sent
if the job is run.
4. Robot Sends a Style Strobe (pulsed bit locks in body style 250ms) Body style
appears in PC Watch Window.
a. The style bit can be turned off.
b. The InProcess bit goes high and the Volume OK bit goes Low.
The system is in a Dispensing Mode (if precharge value is enabled)
5. Robot Sends a 12 bit Group Flow Command signal (0-4095 Max) and the Gun On
signal to start dispensing. The Gun On can go on and off.
6. When the robot is done dispensing for 250ms (gun=off) check for the Volume OK
signal to be LOW. If it is high the device network could be lock up (not
responding) and the robot should fault out.
7. Robot pulses Dispense complete signal. Min. 250 ms.

a. The volume fault table will be looked at and Dispense Volume
and recorded (SPC data)
b. If the volume is out of range a Major fault will occur and the dispense
ready signal will go low.
c. Start the refill sequence on a K device.
d. The InProcess will stay high until the refill is complete.
8. If there were no faults the Volume OK signal will go High and the dispense ready
signal will stay high.
9. Ready for the Next Job.

Inputs/ Automatic
Outputs Sequence
HAND SHAKING
ROBOT OUTPUT DISPENSER RESPONSE RESETS
REMOTE START REMOTE STARTING ON WHEN DISPENSE J-BOX IS OPERATIONAL
FAULTS ARE RESET
BCD ID NO RESPONSE
ROBOT IN CYCLE ON IS DISPENSE WET
VOLUME OK - OFF
VOLUME FAULTS - OFF
OFF IS DISPENSE DRY IF TURNED OFF DURING DISPENSE
CYCLE, CURRENT PROCESS IS
ABORTED, NO FAULTS GENERATED
STYLE STROBE IN PROCESS GOES ON IF CYCLE COMPLETE GOES ON
(MUST TURN OFF START OF DISPENSE CYCLE ABORT DISPENSE
BEFORE END OF
CYCLE) READ AND STORE BODY ID (BCD) IF ROBOT IN CYCLE GOES OFF
PRECHARGE DISPENSER ABORT DISPENSE
DISPENSE GUN ON READ AND FOLLOW ANALOG IF CONFIGURED

PURGE REQUEST GOES OFF
PURGE IN PROGRESS GOES OFF
DISPENSE COMPLETE FAULTS TURN ON IF EXIST INPUT MUST TURN OFF FOR NEW CYCLE
(AT END OF CYCLE, VOLUME OK ON IF EXIST
DISPENSE GUN
MUST BE OFF) PURGE TIMER STARTS
RISING EDGE AUTO DEPRESSURIZE TIMER STARTS
DISPENSE COMPLETE IF IN DISPENSE CYCLE PRIOR TO GUN ON, ENDS DISPENSE
(ANY OTHER TIME) CYCLE AND FAULTS ARE GENERATED
IF DISPENSE CYCLE NOT STARTED, NO ACTION
PULSE AT BEGINNING OF CYCLE - OPTIONAL, PURPOSE IS TO RESET
PREVIOUSLY ABORTED DISPENSE CYCLE THAT DISPENSER
DOES NOT KNOW WAS ABORTED. MUST TURN ON AND OFF PRIOR
TO NEW DISPENSE CYCLE STARTING (STYLE STROBE).
DISPENSE COMPLETE DISPENSER READY GOES OFF DISPENSER READY GOES ON WHEN REFILLING
(FALLING EDGE) IS COMPLETE AND ALL ROBOT CONTROL
SIGNALS ARE OFF
1. Change the style select macros (there is one for E1 & E2) and add a wait statement for the
“INPROCESS” signal to equal OFF at the start of the process.
Equipment #1 In process is DI 162 and Equipment #2 is DI 226
a. Add a fault time out across the wait statement for about 2 seconds.
2. Change the dispense complete macro (there is one for E1 and E2) to check the Volume OK signal.
Equipment 1 Volume OK is DI 163 and E2 is DI 227.
a. At the beginning of the macro and a wait statement for Volume OK to equal OFF.
b. After the Dispense Complete Signal E1 DO 177 or E2 DO 241add another wait
statement .
c. Wait for Volume OK E1 DI 163 or E2 DI 227 to equal ON.
d. Add a fault time out across the wait statements for about 2 seconds.
The fault time out across the wait statement prevents the robot from sitting
for extended periods without showing a fault.

Inputs/ Automatic
Outputs Sequence
This Graph
shows bad
TCPP
Programming
This Graph
shows a
normal TCPP
Programming.
Can you find
the glitch?

TCPP Robot
Programming
TCPP or NOT to TCPP that is a very good Question.

Non - TCP Proportional Approach (Direct Voltage):
This approach is used when the application allows for robot speeds to be constant
and so the dispenser flow rates can be constant. Constant speeds can be
maintained by the robot if the motion is straight. However, if the robot speeds are
kept slow enough it will maintain a relatively constant speed though a complex path.
If the robot speeds very greatly or motion is complex the method of programming
becomes quite difficult requiring the programmer to adjust the material flow at a
point where the robot speed changes.
Seal Start (SS) 300mm/s 3m bead @ 3v=1228 Seal End (SE)
Seal Start (SS) 300mm/s 6m bead @ 6v=2457 Seal End (SE)
If the dispense path is very simple and straight direct voltage is normally used. Any
voltage from 0-10v (0-4095) can be used to achieve the bead size. However if the
dispense path is more complicated (see diagraph below) TCPP is normally used.
Direct Voltage is easier to setup then TCPP
31:L SS[101]
11:L SS[102]
6:L SS[101]
36:L SS[102]
30:L SS[1]
5:L SS[1]
7:L 32:L
12:L
8:L 33:L 37:L
10:L 9:L 34:L
35:L
13:L 38:L
14:L 39:L
16:L 15:L SS[103] 40:L SS[108]
17:L SS[102] 42:L SS[102] 41:L
+Y
19:L 18:L SS[104] 43:L SS[109]
20:L SS[102] 45:L SS[102] 44:L
23:L 21:L
46:L 49:L SS[102]
22:L SS[105] 48:L
47:L SS[110]
24:L SS[102]
25:L SS[106] 50:L SS[111]

HOT EDIT
COORDINATES
26:L SS[107]
51:L SS[112]
+X
27:L SE
52:L SE

TCPP Robot
Programming
TCPP Tool Center Point Predict

This approach requires the most complex and costly equipment but has paid
for itself by making dispense robot programming less of an art. This approach
was developed solely for the purpose of reducing programming complexity
in conjunction with improvements in bead control. This method is interchangeable
for Extruding or streaming, however, extruding adds more complexity for the robot
programmer. The basic intent is to have dispensing flow control tied directly to
the speed of the robot in such a fashion that the robot programmer can change
robot speeds as required to address the specific application without having to adjust
flow control commands to the dispensing equipment. Bead quality should not be
effected when robot speed varies. This involved three basic concepts to make this
a reality;
1. The flow control signal from the robot to the dispenser must be sent before it
is actually required (equipment delay).
2. The flow control signal must be scaled so that at various robot speeds the
signal received by the dispensing equipment is correct for that robot speed.
3. The dispensing equipment must be responsive enough to match the
accel/decel changes of the robot. The Robot/Dispense combination for these
three items is as follows;
1. The Robot controller accurately predicts the TCP (tool center point) velocity
which is adjustable up to 200ms in advance of any programmed point.
2. The scaling of the signal will be determined during Bead Width Calibration
during set up which is a Bead width (volume) vs. voltage relation.
3. The flow control shot meter is directly coupled to the dispensing gun
providing response of about 50 ms which is matched to the time when the
TCP (Tool Center Point) velocity is provided.
Dispense Response Requirements

Shifted Response Representing 50ms of Robot TCP Predict
Required Pressure Tolerance Range w.r.t TCP Command Signal
600
1800
500
1600
400
This graph shows the robot Flow 1400
command TCPP response. The 300

dispense path is the p panel with 1200
two corners one sharper than the 200TCP Speed

Robot Robot TCP Speed
1000 Dispens
Range, +/- 50psi
other
100 800
0 600
1 51 101 151 201 251 301 351 401 451 501
Sample Rate, 100 Hz

TCPP Robot
Programming
End of Arm Tool TCP

End-of-arm tool TCP must be set up prior to dispensing material, the tool center point
must be moved from the sixth axis faceplate to the tip of the tool. Use the most
accurate method provided by the robot manufacturer to teach the robot TCP. Put a 1 ”
teach tip in place of the nozzle and teach the TCP at the pedestal stand. However,
through the use of simulation or physical studies it may have been deemed necessary
to extend the TCP to a length that makes sense for the individual applications. Always
verify the TCP is correct by selecting the robots tool coordinate motion and align the
teach tip pointer with the registration stand pointer and then rotate about all axes, the
teach tip should remain fixed on the registration stand pointer. If the teach tip does not
stay fixed verify that the manufacturers procedures have been correctly followed and
retry. If you cannot teach an accurate TCP contact the Manufacturer for assistance.
It is recommended that when installing the Tool Center Point the that the six point
method is used.
USER FRAME / Work Object Frames

The User Frame or work object frame is set up using the right hand rule so that (+)
positive X is the same direction as the flow of the line or part. This is a practical way to
set up the work object frame so as to spend little time discovering the Cartesian
coordinate directions when manipulating path positional data. The most efficient way to
select an origin for a work object frame for a single robot application is to chose a point
that it is equidistant form all the points in a path and securely in the robot work
envelope. In the cases where multiple robots are working on the same part in the same
coordinate system it would make more sense or select the center of gravity of the work
object to accommodate global offsets as in the case of vision. The origin can be found
by moving the robot to the desired point in space and writing down the X,Y,Z
coordinates. These coordinates should be rounded off to the nearest ones place and
then manually entered into the X,Y,Z coordinates of the work object frame. At this point
W,P,R should all be zero which indicates that the frame is in line with the robot world
frame. Next, determine the amount of rotation, in 90º increments, needed to alien the
world frame of the robot so that its (+) X direction points in the direction of the flow of the
part. For a Fanuc robot enter that number in the R coordinate of the work object frame.
For an ABB robot enter the correct number for the quaternians. Record the numbers to
the documentation accompanying the robot controller under setup information.
NOTE: A user frame must be used if the program is using RTCP (Remote Tool
Center Point)

TCPP Motion
Planning
Motion Planning
It is very important to correctly program the path if TCPP is being used. The
motion should be smooth and not jerky. Try to use the 4th, 5th and 6th axes as Little
as possible. When these axes are moved they accelerate the flow command
signal. The signal in no longer stable and starts to oscillate. Try to do most of the
motion with the 1st, 2nd and 3rd axes. The following are some programming rules
that help create better dispense beads:
1. Do – program the path in Linear motion not Joint or circular.
2. Do Not – change the coordinate system during dispensing. This include leading
in and leading out.
3. Do – A lead in and lead out point is required before a SS or SE. Normally the
point is 4 inches before the bead start or end.
4. Do No run the dispense equipment if the command voltage is over 80% of the
signal. The system will not repeat.
5. Try to run the equipment in the 40 to 60% command voltage range.
6. Do Not run an adhesive over 100ºF. It will accelerate the curing of the material.
7. Have batch compensation OFF and the Global Scaling at 100% and the Offset at
0 when programming.
8. Do not use fine points when programming
3
1
2
Most panels are not flat and the preferred dispense orientation is perpendicular from the
panel (see diagram above). When the dispense head is re-orientated the 4th, 5th and 6th
axes must be used. To do this it is best to use the motion of the robot. Start at point #1
and insert a node perpendicular to the panel. Move the robot to point #3 and insert another
node. Move the robot from node 3 to node 1 at a slow speed. Stop the robot halfway and
only use the first 3 axes to move the robot to point #2. If more points are needed so that
the arc is smooth add them in the same manner. When finished the robot will have a
smooth motion and a gradual change in the flow command signal.

TCPP Motion
Planning
Motion Planning
The Process of doing a corner is very simple with TCPP. Just put a point in the
corner and a lead in and lead out point about 1.5 inches (3.81 centimeter) from
the corner point. The normal robot motion will round the corner with 100 CNT.
To make the corner sharper lower the CNT values in the corner until the
sharpness of the corner is obtained. See Example below. Notice that the lower
the CNT value are set the sharper the corner are. The robot will slow down in the
corners and the command voltage will drop automatically – otherwise the corners
will have extra material in them. If direct voltage is used the voltage needs to be
changed at all three points of the corner.
NOTE: DO NOT USE A CNT VALUE BELOW 50.
When teaching the robot path program. It is very important to try to keep the nozzle
perpendicular from the panel. It is not always possible to do this – if the nozzle needs
to be angled try to have the bead follow instead of leading. This will effect the look of
the bead. It is very important to find the robot speed Before TCPP values are
adjusted.
Ideally keep Have the bead Last choice

the nozzle follow the have the bead
perpendicular nozzle lead.
Robot Direction

TCPP Dispenser
I/O
Setting Up Dispenser I/O.

The next step is understanding the associated data fields in the Fanuc controller that
are associated with dispensing.
a. The Menu-/1/O-(type) dispenser.
b. The Inputs and outputs that are related to the dispenser must be assigned. If
a SS - SE (seal start or seal end) is entered into the path program the device
net digital signal must correspond. This links the device net I/O to the SS &
SE commands.
c. Without this information when a SS1 is commanded nothing will happen.
d. If the robot has two equipments set up there will be a screen for E1 and E2.
press next and select equipment number to see the other equipment.
e. Refer to the robot I/O to set this information.
NOTE The number of the currently selected equipment is displayed in the middle of the title
line on every screen. The currently selected equipment for the screens in this procedure is
equipment 1, E1. Also your screen will differ depending on options.
I/O Sealing In E1
Dispensing Equipment
NAME IN PT SIM VALUE
1 Dispenser Ready: DI [ 1] U OFF
2 In-Process: DI [ 2] U OFF
3 Volume Fault: DI [ 3] U OFF
4 Major Fault: DI [ 4] U OFF
5 Minor Fault: DI [ 5] U OFF
6 Automatic Mode: DI [ 6] U OFF
7 Manual Mode DI [ 7] U OFF
To change between the input and output screens , press F3, IN/OUT. You will see a screen
similar to the following.
I/O Sealing Out E1

Dispensing Equipment
NAME OUT PT SIM VALUE
1 Open gun: DO [ 1] U OFF
2 Flow Command: GO [ 1] U 0
3 Style Bits: GO [ 2] U 0
4 Style Strobe: DO [ 2] U OFF
5 Dispense Complete: DO [ 1] U 0
6 Remote Start: GO [ 2] U 0
Note: This screen is very handy to use – The outputs can be fired and
the inputs can be monitored.

TCPP Tuning the
Dispenser
Tuning the dispense equipment
1. The first step in this process it to complete the path program. It is essential to
know the robot speed. All of the adjustments for TCPP must be done at the
normal run speed of the robot. The robot path program is normally taught first so
that the cycle time can be established. If the cycle time is not met the path may
need to taught faster.
2. Create a path that is a straight line with a SS and SE that is 1 Foot or 30

centimeters long.
3. Using the Setup Page select constant

voltage and set it to 5V.
4. Run the path program and note the bead size. The bead size will not normally
be the size you need. It will need to be adjusted.
5. To adjust the bead size the following options may be used.

a. Raise or lower the voltage. If the voltage becomes above 7.5 volts or
below 2 volts. Another variable will need to be changed.
b. Adjust the material temperature – Higher will increase the bead size and
lower will decrease the bead size.
c. Change the nozzle size. - Larger will increase the bead size, however the
velocity of the stream will decrease – the robot path may need to be closer
to the panel.
d. A small nozzle will make the velocity of the stream increase (shoot farther)
but increase the chance for a tip plug.
6. The Dispense system needs to run in the mid range before TCPP calibrations are
attempted. If the equipment is running a 2 or 9 volts flow command the system
will not be able to alter the flow command enough to effectively make TCPP
work.
SS Robot Speed same as path program SE
Use the voltage in the Constant / Manual Setup screen to setup

desired flow rate. (5v = 2045)

TCPP Seal
Schedules
Seal Schedules
1. The Seal Schedules can be accessed by depressing the DATA button and then F1
Seal Schedules.
2. This is where the system can be set up for direct voltage or TCPP Bead Width
calibration. There are 30 seal schedules for each equipment. More than one seal
schedule or type (TCPP or Direct Voltage) can be used in a path program. A signal
path program can consist of direct voltage and TCPP Bead Width Variables.
a. An example of using both variables in one program would be if there was an
area of the panel that needed to be filled. If BW was chosen and the robot
was not moving the command signal would be 0.
•1 Press DATA.
•2 Press F1, [TYPE].
•3 Select Seal Sched. If the following screen is not displayed, press F2, LISTING. You will see a screen
similar to the following.
NOTE The number of the currently selected equipment is displayed in the middle of the title line
on every screen. The currently selected equipment for the screens in this procedure is equipment
1, E1.
DATA Seal Sched

E1Variable Orifice System
Schd Value Flow Type Comment
1 10.0 mm BW TCPP FOUR DOOR LR
2 0.0 mm BW TCPP
3 4V Volts
4 0.0 mm BW TCPP
5 0.0 mm BW TCPP
6 0.0 mm BW TCPP
7 0.0 mm BW TCPP
8 0.0 mm BW TCPP
9 0.0 mm BW TCPP
•4 Set the values for each schedule as appropriate.

• 5 To display more information about a single schedule, press F2, DETAIL. You will see a
screen similar to the following.

TCPP Seal
Schedules
Seal Schedules
1. Under The dispense style depress F2 for the LISTINGS of the body styles. Another
screen will show some of the specific adjustable information for each individual body
styles.
DATA Seal Sched E1

Variable Orifice System
1 Schedule # 1
2 Flow type: TCPP Bead Width
3 Flow model: LINEAR
4 Flow rate: 3.00 mm
5 Guns used: 1--***
6 Equip. ant-time: 0 ms
7 Eq. additn. ant-time: 0 ms
8 Gun on ant-time: 0 ms
9 Gun off ant-time: 0 ms
10 Bead shaping (BS): 0.0 psi
11 BS on ant-time: 0 ms
12 BS off ant-time: 0 ms
13 Pre-pressure time: 0 ms
14 De-pressure time: 0 ms
15 Correction factor: 1.0
16 Correction bias: 0v
17 SS time offset: 0ms
18 SE time offset: 0ms
• To return to the LISTING screen , press F2, LISTING.
2. The information that we will normally use is:

a. (2) Use TCPP Bead Width or Volts (direct voltage).
b. (3) Linear should be used in all configurations.
c. (4) Flow rate should be the size bead that is required or if direct voltage is
used a voltage number 0-10v can be inserted.
d. (5) Guns used normally set to 1
e. (6) Equipment. Ant-Time is the equipment delay. This variable sends the
flow command before the robot actually gets to the node. Without this
variable set correctly TCPP will not work. This is the reaction time of the
mechanical equipment.
f. (7) Gun on ant-time This item indicates the anticipation time between
when the robot reaches the destination position and when the gun is
turned on. If you want the gun to turn on before the robot reaches the
destination position, set Gun on ant-time to a negative number. If you
want the gun to turn on after the robot reaches the destination position,
set Gun on ant-time to a positive number.

TCPP Seal
Schedules
Seal Schedules
Continued:
DATA Seal Sched E1

Variable Orifice System
1 Schedule # 1
2 Flow type: TCPP Bead Width
3 Flow model: LINEAR
4 Flow rate: 3.00 mm
5 Guns used: 1--***
6 Equip. ant-time: 0 ms
7 Eq. additn. ant-time: 0 ms
8 Gun on ant-time: 0 ms
9 Gun off ant-time: 0 ms
10 Bead shaping (BS): 0.0 psi
11 BS on ant-time: 0 ms
12 BS off ant-time: 0 ms
13 Pre-pressure time: 0 ms
14 De-pressure time: 0 ms
15 Correction factor: 1.0
16 Correction bias: 0v
17 SS time offset: 0ms
18 SE time offset: 0ms
g. (9) Gun off Ant:time. This item indicates the anticipation time between
when the robot reaches the destination position and when the gun is
turned off. If you want the gun to turn off before the robot reaches the
destination position, set Gun off ant-time to a negative number. If you
want the gun to turn off after the robot reaches the destination position,
set Gun off ant-time to a positive number.
h. (10) Bead shaping is normally not used. The BPR system uses bead
shaping and calls out a GO = xxxx directly from the path program.
I. (15) The Corrector Factor should always be set to 1.0 this value
multiplies the flow command by a percentage (1.0 = 100%).
j. (16) Correction bias should always be set to 0v this value adds or
subtracts direct voltage to the flow command.
The rest of the values are not mentioned and are normally not used:
NOTE: If multiple seal schedules are used the specific information for each body must
be duplicated in each seal schedule. If the values are entered in one schedule
they are NOT entered in all schedules.

TCPP Dispenser
Setup
Dispense Equipment TCPP Setup

This screen is under MENU/SETUP/DISPENSOR
These set of variables Setup the TCPP bead size requirements.
Some of the newer fields will ask for the robot speed. This would be the normal speed of
the dispense path.
EQ SL Setup D1
R-J3 Vari. Orifice Dispense System
Flow Rate Calibration
Calibration status: DEFAULT
Seal sched in MOV_SEAM: 30
1 Flow rate type: TCPP Bead Width
2 Desired flow rate: 3.0 mm
3 Sample program: [MOV_SEAM]
4 Home program: [MOV_HOME]
5 TCPP BW scale factor: 1.000
Seal Schedule in Mov_seam is the default calibration seal schedule when

running the automatic calibration program (Not Recommended to run).
1. Desired flow rate indicates the target flow rate that will be used for this
calibration. Set this to the flow rate that will be used most often in your
process. Editing this item is the same as editing Flow rate type in the
specified sealing schedule, which is sealing schedule 30. If one
equipment is dispensing 2 bead sizes such as a 3mm and 5mm. An in-
between size should be chosen - 4mm. This is one of the values that the
command signal (0-4095) uses to scale itself.
2. TCPP BW scale Factor should be set to 1.000. This is an internal factor
not easily changed. Do not run the sample programs as the will alter this
scale factor.

TCPP Dispenser
Setup
Dispense Equipment TCPP Setup
These set of variables tune the TCPP variables into the dispense equipment. These are
calibrations variables used to tune the dispense bead into the required bead size.
Setup Scaling D1
R-J3 Vari. Orifice Dispense System
1 Material Factor 1.00
2 Flow Rate Bias 0.00v
3 Minimum Flow Command 0.00v
4 Flow command AOUT type Volts
5 Use Default ACC: Disable
6 Default ACC 20
CALIBRATIONS
8 Meter Max Speed Complete
9 Flow Rate Control
1 Before starting verify that the (8) Meter Max Speed calibration has been
completed. If not follow these steps.
a. Move the curser until COMPLETE is highlighted.
b. Press (F3) Start on the teach pendent
c. Verify the Maximum voltage is 10.00v
d. Verify the voltage step is 0.10v
e. Continue without moving the robot and the calibration will be
complete.
2. Material Factor is a multiplying scale factor of the bead. This factor sets the
major size of the bead. Mostly controls the large size of the bead in the
straight away. This is when the command signals are the greatest.
3. Flow Rate Bias adds or subtracts voltage to the command signal. This factor
sets the minor size of the bead. When the robot goes through a corner the
material factor command signal can go to zero. If this happens the corners
will not have any material. To offset this voltage is added to the signal to
make the corners the correct size.

TCPP Equipment
Delay
Finding the Equipment Delay.
One of the first requirements of dispensing is to find the equipment delay. The
only way that this can be achieved it to run a specific program and change the
equipment anti-time variable listed in the DATA variables.
ZIGZAG
ZIGZAG is a program that is used to establish the equipment delay. This
program MUST be run at the same speed that is in the normal run dispense path
program. Follow the example below as a path program.
4 in. 12in. The robot speed must for all nodes must be
the same and match the normal dispense
speed of the robot.
Approach point
SS30 with CNT 100
12 in.
Corner nodes with CNT 50
SE with CNT 100
End Point
12in. 4in.
Create the program on the dispense part or something strong enough that
one can scrap off the material. Mark the seal start and the seal end
positions. Use seal schedule 30 to set up the bead size.

TCPP Equipment
Delay
Finding the Equipment Delay.

Use seal schedule #30 and verify that the correct be size is set up in the DATA/
Seal Schedule and that the flow type is TCPP bead width.
In MENU/SETUP/DISPENSER make the following adjustments to the bead size..
1. Increase the Material factor to 5.0. This will give a very high scaling factor which
will make the large part (straight away) part of the bead very big. The bead size
is not important at this time – the equipment delay is.
2. Decrease the Offset Bias to -1.5v. This will make the smaller part of the bead
(corners) look like they almost have no material.
3. Run the bead path – Make sure that a style bit and strobe is sent otherwise the
system will run in manual voltage.
a. The straight away should look heavy.
b. The corners should have too much material.
c. There should be a neck down in the bead after the corners.
4. The neck down in the bead after the corners is the actual equipment delay. The
robot is sending the flow command signal at the actual time it approaches the
node. It take a few milliseconds for the dispenser to respond.
5. Adjust the equipment delay in the DATA SEAL SCHEDULE menu.

a. Normally a 1K system running 500mm/s will have a equipment delay of
50ms.
b. Keep adjusting the equipment delay until the neck down area is directly in
the corners.
6. Transfer the equipment delay to all of the seal schedules that the program will
use.
NOTE: WHEN RUNNING THE BEAD PATHS THEY MUST BE RUN A 100% SPEED

TCPP Gun On-Off
Delay
Adjusting the Gun On-Off Delay
Use seal schedule #30 and verify that the correct be size is set up in the DATA/ Seal
Schedule and that the flow type is TCPP bead width.
1. Verify that the equipment delay is in the seal schedule that is being used. The
equipment delay will effect the gun on and gun off anti time.
2. Run the path and the bead should start slightly after the node is programmed for
the SS (Gun On).
a. This item indicates the anticipation time between when the robot reaches
the destination position and when the gun is turned on. If you want the gun
to turn on before the robot reaches the destination position, set Gun on
ant-time to a negative number. If you want the gun to turn on after the
robot reaches the destination position, set Gun on ant-time to a positive
number.
b. Adjust the Gun On ant-time until the bead start is directly on the SS node.
3. Run the path and the bead should end slightly after the node is programmed for
the SE (Gun Off).
a. This item indicates the anticipation time between when the robot reaches
the destination position and when the gun is turned off. If you want the gun
to turn off before the robot reaches the destination position, set Gun off
ant-time to a negative number. If you want the gun to turn off after the
robot reaches the destination position, set Gun off ant-time to a positive
number.
b. Adjust the Gun Off ant-time until the bead ends directly on the SE node.
Adjust the bead size.
1. Run the bead path and adjust the Material Factor in the
MENU/SETUP/DISPENSOR screen until the correct bead size is achieved.
2. The corners should be undersize. Adjust the Offset Bias in the

MENU/SETUP/DISPENSOR screen until the correct bead size is achieved.
a. When the Offset Bias is increased the bead size on the straight away will
increase. Just lower the Material Factor to compensate.
3. Adjusting the Material Factor and Offset Bias are set by trial and error method.
Trying to use the formula rarely works and is a waste of time.
NOTE: WHEN RUNNING THE BEAD PATHS THEY MUST BE RUN A 100% SPEED

TCPP Running the
Path
Running the Dispense path
The TCPP variables have been defined. They just need to be transferred to the seal
schedule that is being used for the dispense bead path.
a. Go to the listing for seal schedule 30.
b. Copy the seal schedule and paste the values in the seal schedule that is
being use for the dispense path.
Run the dispense path that was programmed earlier. Some of the corners might need
to be adjusted by adjusting the CNT percentage values.
If the bead size is not correct slight adjustments can be made to the
MENU/ SETUP/DISPENSER Scaling Factor variable.
NOTE: There is a MENU/SETUP/DISPENSER set up screen for equipment #1 and

another screen for equipment #2. If the robot is using 2 equipment. It is very
easy to get these mixed up.
YOU HAVE JUST SET UP YOUR FIRST TCPP BEAD WIDTH CALILBRATION.

Robot
Programming Payload
Robot Motion
If the robot motion is not smooth some additional settings may be required.
Listed below are some variables that have helped programmers set up the robots and
tune in the TCPP values. The variables are located under
Menu/System/(type/Variables).
The robot payload from Fanuc is set to the maximum value of 120.000 . If the payload
is lighter and the robot program is running faster than 500 mm/s the corner of the
program could bounce. To fix this change the variable
$GROUP - UPR_T/enter/enter/enter/$PAYLOAD (item 22).
Pounds X 2.2 = Kilo. The variable is in Kilo’s.
Below are some standard weight and mass variables for a single system.

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Fanuc Robots with Device Net

JDS402 – Robot Programming

JDS402 Robot Programming 1 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

JDS402 Robot Programming 2 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

The 1K systems use a shot meter as a metering device. The shot

JDS402 Robot Programming 3 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

JDS402 Robot Programming 4 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Devices and what they do:

JDS402 Robot Programming 5 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Voltage Range 0-10vdc Voltage

JDS402 Robot Programming 6 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Trim adjustment screw

The Transducer has a new feature of an trim

JDS402 Robot Programming 7 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Air Servo Valve:

JDS402 Robot Programming 8 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

The Robot Flow Command signal will change the

JDS402 Robot Programming 10 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

1K Dispense Head Sequence of Operation

JDS402 Robot Programming 11 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

1K Dispense Head checking procedure:

This Procedure test the Dispense valve, Refill

JDS402 Robot Programming 12 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

The Autostream 1R system includes a proportional

The Pump station Consists of a single or dual

The Flow monitor measures the material volume for

The Proportional Material Regulator uses the incoming

2000 PSI 50 PSI 1000 PSI

JDS402 Robot Programming 13 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

The Proportional Material Regulator uses

The air servo regulator is the interface

The Material has three gauges that are

JDS402 Robot Programming 14 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

If a fault is on it will be shown with a

This a record of the faults that has a

Fault Problem Solution

JDS402 Robot Programming 15 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Fault Problem Solution

JDS402 Robot Programming 16 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Fault Problem Solution

JDS402 Robot Programming 17 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

JDS402 Robot Programming 18 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Hem Adhesive Bead

Hem Adhesive Ribbon Shaped Bead

Lap Joint Adhesive Bead

After Hem Sealer

JDS402 Robot Programming 19 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Extrusion String Dispersion

Clip Fan (Precision) Spraying

JDS402 Robot Programming 20 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Shown are String dispersion, tip orientation, specialty, extrusion

JDS402 Robot Programming 21 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

Extruding Nozzle Selection

JDS402 Robot Programming 22 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

JDS402 Robot Programming 23 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

This example show the difference temperature can make. The

JDS402 Robot Programming 24 INGERSOLL-RAND © 2004 ALL RIGHTS RESERVED

364-207 Device Net Communications

The dip switches set the address to