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1. INTERFACE DESCRIPTION
This interface is designed for a Power Wave 450 and a
Fanuc robot using ArcTool software (V1.30P) with
touch sensing and through arc tracking. The interface
responds to all of the ArcTool welding inputs and out-
puts except wire fault and wire stick alarm. All of the
circuitry for touch sensing is internal to the Power
Wave, no external power supply is required. The cur-
rent signal for through arc tracking is supplied by the
Power Wave, no external current sensor is required.
The interface does not control wire feed speed and
welding voltage independently. Rather, the Power Wave
is always operating in a synergic mode and the welding
voltage is programmed as a function of the wire feed
speed. ArcTool software was designed to control wire
feed speed and voltage independently.
Power Wave system uses an arc length trim, the volt-
age cannot be directly controlled. The welding voltage
settings in the robot controller are interpreted by the
Power Wave as a trim setting. Any ArcTool function
which tries to set the voltage to zero and control the
wire feed speed is actually only setting the arc length
trim to the minimum. Refer to the Operation section for
a complete description of arc length trim. Any function
which tries to set the wire feed speed to zero and con-
trol the voltage is actually only setting the wire feed
speed to the minimum speed of the selected process.
The following is a list of functions which do not work as
intended by Fanuc due to the synergic operation of the
Power Wave:
1.1 WELDING VOLTAGE
In this interface all welding voltage settings must
be thought of as an arc length trim. This arc
length trim will increase or decrease the arc volt-
age for a specific wire feed speed setpoint. The
scaling in the robot controller is setup to allow
voltage numbers between 50 and 150. A voltage
number in the robot controller of 100 equals the
nominal voltage (no trim adjustment) for the
selected wire feed speed. If the arc length needs
to be increased then the voltage trim number is
increased. For example, if a voltage number of
115 is used then the arc voltage will increase too
approximately 15% above the nominal voltage
for the wire feed speed setpoint in use.
1.2 WIRE BURNBACK FUNCTION
The burnback function controlled by the robot
controller will not operate properly. The function
was setup to use a wire feed speed of zero while
setting the welding voltage to some level. The
system will produce the minimum wire feed
speed for the selected procedure and a voltage
trim for that selected wire feed speed setpoint.
ROBOTIC INTERFACE
1.3 WIRE STICK RESET FUNCTION
Since the
1.4 COLD WIRE INCHING FUNCTION
2. ROBOT SIGNAL DESCRIPTIONS
2.1 VOLTAGE COMMAND
2.2 WIRE FEED SPEED COMMAND
POWER WAVE 450
The solution to this problem is already built into
the Power Wave. At every "arc end" the Power
Wave automatically goes through its own burn-
back routine.
The wire stick reset function controlled by the
robot controller will not operate properly. This
function is very similar to the burnback function.
It was intended to use a wire feed speed of zero
while setting the welding voltage to some level.
For the same reasons as wire burnback it will not
operate properly. The burnback routines in the
Power Wave have been optimized for each weld-
ing procedure and are very reliable. If any wire
stick problems occur, the burnback routines in
the Power Wave can be programmed to correct
the problem.
The cold inching wire feed speed cannot be
changed by the robot controller. It is always set
to 80 IPM. A variable cold inching speed is not
possible with the current architecture of the inter-
face.
This is an analog output from the robot controller
with a range of 0 to 10V. Since the Power Wave
is always running in the synergic mode an output
voltage cannot be set. The voltage command is
used as a voltage trim for the active workpoint.
The voltage command limits in the robot con-
troller are entered as 50 to 150V. This is done so
that the nominal trim setting (100V) is not con-
fused with a welding voltage.
This is an analog output from the robot controller
with a range of 0 to 10V. The wire feed speed
command sets both the wire feed speed and the
synergic output of the Power Wave. The wire
feed speed command limits in the robot con-
troller are entered as 50 to 770I PM for a stan-
dard drive head and 80 to 1100 IPM for a high
speed drive head.
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Troubleshooting
