1、6000 UIR 培訓ch Rexroth PSQ 6000UIR 自適應系統培訓Electric Drives and Controls1sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UI 調整的功能過程參數使用:1.) 初級或者次級電流和2.) 電極的電壓降= 焊鉗臂的次級電壓電流次級電壓= 焊接時的動態電阻

2、是由過程參數電流和電壓計算出來的 .= 計算出焊點的能量平衡i(t)r(t)Current /CurvesElectric Drives and Controls2sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UI 調整的功能電流電壓實際電阻參考電阻Electric Drives and Controls3sby

3、ch RexroG, even and espelly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UI 調整的功能電極電壓UI調節電流調節對電流和樣本曲線時間發出指令實際電流值Electric Drives and Controls4sbych RexroG, even and espelly in cases of proprietary rights applicat

4、ions.We also retain soleer of disal, includings relating to copying, transmisand dissemination.電阻焊接如何工作電阻焊接只是眾多金屬連接方法的一個.在這個過程中能夠,將一定數量的電流通過已經加壓疊加在一起的兩層或者多層金屬組合, 在接觸面上產生熱量. 產生的總的熱量可以通過下面的公式表示:Q=I2RtQ = 產生熱量, 焦耳I = 焊接電流,R = 工件電阻, 歐姆t = 通電時間, 秒焊接電流(I)和通電時間(t)是由電阻焊接電源控制的. 工件的電阻(R)是焊接壓力和使用的材質決定的.焊接電流或者時

5、間輕微的改變能夠對焊接熱量產生很大影響.Electric Drives and Controls5sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UI 調整的功能使用的調整特性:1.) 能量守恒:當焊接時間延長被開啟,調節功能確保實際被焊接焊點的能量與樣本焊點能量的關系是: E實際 = E樣本2.) 飛濺補償:發現

6、飛濺以后.金屬液體的損失將會通過延長焊接時間來補償.3.) 撓動的補償:過程參數背離樣本，引起了撓動，能被發現并且通過電流和時間的改變來補償.變化值取決于撓動的類型.Electric Drives and Controls6sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 組成部分質量控制模塊XQR6000傳

7、感器電纜Electric Drives and Controls7sbych RexroG, even and espelly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 電壓測量電纜的接線電纜高柔韌性的電纜變壓器對于三核控制器XQR模塊已經集成到主板上，電壓檢測線接到X3的6，7腳，8腳為Electric Drives and Controls8sbych Rex

8、roG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.控制器PSQ質量控制卡 X8A接線端子1，3LED指示燈Electric Drives and Controls9sbych RexroG, even and espe lly in cases of proprietary rights applications.We also re

9、tain soleer of disal, includings relating to copying, transmisand dissemination.COM通訊情況綠燈亮，數據處理模塊CAN總線通訊正在運行紅燈亮，數據處理模塊CAN總線通訊出現故障RUN運行狀況綠燈亮，模塊工作沒有錯誤紅燈亮，模塊運行出現錯誤UIR: 安裝越近越好.電壓檢測點離焊鉗電目的: 使得反饋信號的損失最小,得到更準確的接觸電阻.安裝傳感器電纜遠離次級動力電纜，最好沿著水管.傳感器電纜:最大長度100m 螺旋狀,線 2 x 0.75層的最大電纜長度: 大約1m沒有當使用中介接頭的時候, 端口或者柜子的接地排上.

10、線一定要連接.線可以接到UI板的接線Electric Drives and Controls10sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UI 調整的操作焊接一個合格的焊點電流 / 電壓 / 電阻曲線樣本調整電流和焊接時間改變實際曲線和樣本曲線進行比較Electric Drives and Controls1

11、1sbych RexroG, even and espelly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UI 調整的操作1.確保修磨后的焊槍電阻穩定在CP6現場，通過251號程序進行電阻KSR模式下焊接優化焊接參數: 電流,時間和壓力.消除飛濺并且完全保證良好的焊接質量.樣本電阻曲線電阻曲線是由過程參數建立的.這將作為以后焊接的參考樣本.UI調整開關打開激活所有相關程序

12、的調整功能.在焊接過程中使用UI調整和..確保焊接過程的穩定性并且為UIP和PSF設定限制。Electric Drives and Controls12sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR: 撓動的補償不同的涂層焊點之間的分流板間裝配不好膠水電極磨損不同的板厚焊接多層板焊接不同的壓力

13、變化Electric Drives and Controls13sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 普通參數焊接參數編程和UIR使用同一個作當前控制器內所有程序的全局設置“Robot“模式選擇用于自動工位Electric Drives and Controls14sbych Rex

14、roG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 編程參數為個別程序進行設定Electric Drives and Controls15sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retai

15、n soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 編程參數測量調整Electric Drives and Controls16sbych RexroG, even and espelly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面:

16、 測量參數黃色：沒有激活綠色：已經激活焊接和飛濺計數測量Electric Drives and Controls17sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.監控狀態調整狀態檢查飛濺的參數電阻減少的百分比黃色：沒有/無效的樣本曲線白色：有效的樣本曲線UIR 用戶界面 : 調整參數左側顯示綠色說明當前程序的UI

17、R功能已經啟用焊接電流的限定調整Electric18sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.焊接時間延長的開啟在焊接過程中調整開始的時間UIR 用戶界面 :參數程序的開啟功能右側顯示綠色說明Monitoring當前程序的能已經開啟功Electric Drives and Controls19sbych Re

18、xroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 :參數功能可以對每一個監督參數分別激活.依靠過程可以適合不同的變量.通常PSF和 UIP是使用最多的鑒定依據Electric Drives and Controls20sbych RexroG, even and espe lly in cases of propr

19、ietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 :參數Upper Tol.當參數被開啟以后, 參數實際值的點Desired Value將會與期望值和公差帶一起顯示。Cond. Tol. Low er Tol.Electric Drives and Controls21sbych RexroG, even and espe lly in cases of proprietary rights a

20、pplications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 焊接參數的設定飛濺臨界點kA焊接合格臨界點Electric Drives and Controls22sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, tra

21、nsmisand dissemination.焊接飛濺區域焊接完全合格焊接不合格區域UIR 焊接參數的設定飛濺臨界點kA焊接不合格臨界點Electric Drives and Controls23sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.焊接飛濺區域好的焊接參數 - KSR好的焊接參數 - UIR焊接不合格區

22、域UIR 焊接參數的設定焊接飛濺區域飛濺臨界點KSR的電流增加取決于熱量遞增.沒有飛濺kA焊接不合格臨界點焊接不合格臨界點Electric Drives and Controls24sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 焊接參數的設定飛濺臨界點中的KSR參數，存在飛濺kA焊接不合格臨界點Elect

23、ric Drives and Controls25sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.在UIR調整焊接不合格區域焊接飛濺區域UIR 焊接參數的設定由于UIR基于能量調整的原理（見第6頁），在KSR階段的前提下，參數設置盡量取接近下限的值在保證焊接質量飛濺臨界點UIR調整過程中的焊接參數并且沒有飛濺kA焊

24、接不合格臨界點Electric Drives and Controls26sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.焊接不合格區域焊接飛濺區域UIR 用戶界面 : 創建樣本曲線在開啟UIR之前打開圖中通用設定中的測量、調整以及 UIR設定中的測量選項Electric Drives and Controls27

25、sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 創建樣本曲線如果在KSR模式下焊接參數已經得到完全優化，然后就可以程序創建樣本曲線.選擇“Setup” 和“UI Setup” 界面中的“Recording Mode” 按鈕.Electric Drives and Controls28sbych

26、 RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 創建樣本曲線選擇需要 線的控制器.電阻曲通過點擊“Start recording”按鈕激活模式.Electric Drives and Controls29sbych RexroG, even and espe lly in cases of propri

27、etary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 創建樣本曲線時所需焊接的點數最少是一個完整的電極修磨循環.至25條曲線。少當所達到所需要的曲線數目時,停止.Electric Drives and Controls30sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retai

28、n soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 創建樣本曲線如果焊接很穩定，電阻曲線形狀幾乎一致，可以用來作為樣本曲線Electric Drives and Controls31sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmi

29、sand dissemination.UIR 用戶界面 : 創建樣本曲線任何不可接受的曲線可以被刪除.刪除當前曲線Electric Drives and Controls32sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.被選中的相關曲線顯示紅色UIR 用戶界面 : 創建樣本曲線也可以同時刪除選擇的多條曲線Elec

30、tric Drives and Controls33sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.有飛濺的曲線將被刪除UIR 用戶界面 : 創建樣本曲線平均電阻曲線顯示紅色的,最大值和最小值的曲線同樣被顯示.如果顯示出來平均電阻可以接受，就可以傳送到控制器中作為所選程序的樣本曲線.創建的樣本曲線同樣可以保存到PC

31、中.Electric Drives and Controls34sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 切換到調整模式當樣本曲線被傳送到控制器中，被選程序的調整就可以激活.顯示出來的參數需要被設置Electric Drives and Controls35sbych RexroG, e

32、ven and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : UIR 曲線的觀察“Diagnosis” 窗口和“PSQ”界面需要被選定才能看到UIR曲線當焊接時，實時的曲線將會在此處顯示Electric Drives and Controls36sbych RexroG, even and espe lly in cases of pr

33、oprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : UIR 曲線的觀察激活“Stop”按鈕, 這可以使用條狀按鈕選擇先前數次焊接的曲線圖.Electric Drives and Controls37sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain solee

34、r of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : UIR 曲線的觀察上一次焊接的曲線同樣可以在“Programming”的“UIR Reference” 界面看到.曲線不會自動出現在這個界面，需要通過 “Actual curve-Timer”按鈕從控制器中重新找回.Electric Drives and Controls38sbych RexroG, even and espelly in cases of proprietary rights applications.We als

35、o retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 控制器中UIR調整功能預覽與檢查預覽首先查看哪些程序的UI測量激活可以通過預覽功能來查看UIR的使用情況在控制器中往往有數個程序，Electric Drives and Controls39sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, in

36、cludings relating to copying, transmisand dissemination.UIR 用戶界面 : 控制器中UIR調整功能預覽與檢查接著檢查哪些程序的UI調整激活圖中可以看到102號程序的UI功能未開啟，接下來對照點表確認102號程序的應用情況Electric Drives and Controls40sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to

37、copying, transmisand dissemination.UIR 用戶界面 : 控制器中UIR調整功能預覽與檢查可以通過屏幕上方的show filter鍵查看某一個控制器的點表點表總覽，Electric Drives and Controls41sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用

38、戶界面 : 控制器中UIR調整功能預覽與檢查可以通過屏幕上方的show filter鍵查看某一個控制器的點表點表總覽，Electric Drives and Controls42sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 控制器中UIR調整功能預覽與檢查可以看到該控制器焊點列表中沒有102

39、號程序的焊點信息， 該點已挪走；如列表中有102號程序，需要重新開啟UI測量，需要向焊接確認是否曲線打開調整功能Electric Drives and Controls43sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 控制器中UIR調整功能預覽與檢查可以選擇一定的時間范圍6000中的LOG功

40、能，可以查看近期焊接故障的發生情況Electric Drives and Controls44sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 控制器中UIR調整功能預覽與檢查單擊Filter Setting可以選擇某一個控制器查看故障信息。對于下圖，2590R01機器人21號程序 PSQ報錯單

41、擊Timer name或Prg，可以根據控制器名或程序號排序。Electric Drives and Controls45sbych RexroG, even and espelly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : 控制器中UIR調整功能預覽與檢查為了不影響生產，可以把該程序的UIR調整功能暫時關閉，在生產結束后聯系相關焊接負責人。而不允許

42、將通用中的調整選項關閉。否則會將控制器中所有程序的調整功能禁用！not Allowed to turn offAllowed to turn offElectric Drives and Controls46sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.6000從中如何提取飛濺數據6000里面有一個飛濺整體預覽頁

43、面.在這個頁面可以給客戶顯示飛濺一個全局預覽在整條生產線上或者在個別控制器上, 在飛濺的發現和后來的避免方面有幫助.這個頁面能以text文檔形式輸出并且倒入excel形式請注意,這功能只能應用在6000版本V1.23.0或者以后的版本.如果你想在焊點列表中的附加需求中看到數據，要確保將焊點列表先從控制器中提取出來。 下面詳細介紹如何提取焊點列表47sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relati

44、ng to copying, transmisand dissemination.6000從中如何提取飛濺數據在提取飛濺數據之前要確保，焊點列表已經被提取出來。點擊 add。48sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.Return to Icons6000從中如何提取飛濺數據選擇Spot Table - T

45、imer.49sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.Return to Icons6000從中如何提取飛濺數據顯示出焊點列表.50sbych RexroG, even and espe lly in cases of proprietary rights applications.We also reta

46、in soleer of disal, includings relating to copying, transmisand dissemination.Return to Icons6000從中如何提取飛濺數據6000中.在下拉式菜單, Function.Spot / Expul Overview (Ctrl+F3)51sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copyin

47、g, transmisand dissemination.6000從中如何提取飛濺數據顯示左側的頁面.選擇數據的類型,焊點名稱或者程序號從下拉式菜單中選擇日期和時間,這是這是所有外推數據的開始.從下拉式菜單中選擇日期和時間,這是這是所有外推數據的結束.如果不管是否有飛濺顯示所有程序或者焊點在此處打勾選擇update顯示數據Electric Drives and Controls52sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal,

48、includings relating to copying, transmisand dissemination.6000從中如何提取飛濺數據數據顯示并且能根據要求通過此頁面頂部的標題被分類.這些信息能被輸出，并且顯示在excel文檔中進行次的%expul.數據是計算出的并且有圖形和數字顯示的Electric Drives and Controls53sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings rel

49、ating to copying, transmisand dissemination.6000從中如何提取飛濺數據54sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : PSF與UIP的設定Pros Stability（過程穩定性）這個結果數值是基于電壓，電流和延長焊接時間計算出來.顯示值涉及的

50、是樣本曲線和實際曲線之間的差異. 實際曲線越偏離樣本曲線，PSF值越低。過程穩定數值一般=100UIP（質量控制因子）這是建立在電阻,電壓,電流和時間上的質量指標.焊接結束后，樣本曲線的焊點會有一個UIP得分，通常為100。之后的焊點會基于能量基礎上與樣本焊點進行比較。得分越高說明焊點能量有過剩，得分越低則有弱焊或虛焊的可能。在設定PSF及UIP公差帶并啟用這兩個功能前，首先要確保修磨電阻的穩定。請看下面的舉例Electric Drives and Controls55sbych RexroG, even and espe lly in cases of proprietary rights

51、applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : PSF與UIP的設定左圖232600R01機器人2014.7.1日16:35分的一次修磨，修磨電阻35微歐超出了公差帶，右圖為17:30分的一次修磨，修磨電阻68微歐，在公差帶內。Electric Drives and Controls56sbych RexroG, even and espe lly in cases of proprietary rights app

52、lications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : PSF與UIP的設定可以看到17:08分，在兩次修磨之間的焊點有UIP超出公差的情況。建議選擇修磨穩定的程序打開PSF和UIP功能Electric Drives and Controls57sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain sol

53、eer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : PSF與UIP的設定在UIP和PSF超出公差帶時，才能繼續生產。CH控制器會實警，點焊接已完成。后續需要人工復位Electric Drives and Controls58sbych RexroG, even and espelly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to c

54、opying, transmisand dissemination.UIR 用戶界面 : PSF與UIP的設定not Allowed to turn off為了不影響生產，可以把該程序的UIR功能暫時關閉，在生產結束后聯系相關焊接負責人。而不允許將通用中的選項關閉。否則會將控制器中所有程序的功能禁用！Allowed to turn offElectric Drives and Controls59sbych RexroG, even and espe lly in cases of proprietary rights applications.We also retain soleer of disal, includings relating to copying, transmisand dissemination.UIR 用戶界面 : PSF與UIP的設定現場很多程序的UIP及PSF是由于樣本曲線與實際曲線差異過大造