DOCUMENTATION

REIS GMBH & CO MASCHINENFABRIK OBERNBURG

General

Title: Operating and programming instructions for ONLINE parameter modification

and display function

Author: Dr. Thomas Rienmüller

Date: 22.07.1999

Control version: RSV / RSV-PCX

Software revision: 3.0 / 10.0

Documentation for level: 2

Date: 14.01.03

Release: i.A. Elter

Original: I:\Dokumentation\Rsv-PCX\Word_Dokumente\Online_1000_GB.doc
 RSV-PCX GENERAL

1 TABLE OF CONTENTS

1 TABLE OF CONTENTS _________________________ 2

2 GENERAL DESCRIPTION _______________________ 4

3 TARGET GROUP ______________________________ 4

4 SAFETY INSTRUCTIONS _______________________ 5

5 CONDITIONS: HARDWARE AND SOFTWARE ______ 5

6 INSTALLATION/CONFIGURATION________________ 6

7 OPERATION __________________________________ 6

8 PROGRAMMING ______________________________ 7
8.1 STRUCTURE DESCRIPTION OF THE “INFO_CNF” FILE _______ 7
8.2 RETRANSCRIPTION OF MODIFIED VARIABLE CONTENTS ___ 13
8.3 REQUEST OF MODIFICATION FUNCTION PER MACRO ______ 14
8.3.1 MPR "INFO_CNF" __________________________________ 15
8.3.2 MAC "ONL_PULSCORR" ____________________________ 17
8.3.3 MAC "ONL_POWER"________________________________ 18
8.3.4 MAC "ONL_ARCCORR" _____________________________ 19
8.3.5 MAC "ONL_EXIT" __________________________________ 20
8.3.6 MPR "CHNG_SYS" _________________________________ 21
8.4 GENERAL NOTES _____________________________________ 24

9 APPLICATION SOFTWARE_____________________ 24

10 ERROR MESSAGES/ DEBUGGING ______________ 25

10.1ERROR MESSAGES ___________________________________ 25

11 GLOSSARY _________________________________ 26

12 INDEX ______________________________________ 26

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2 General Description

The ONLINE display and parameter modification function allows

to display process parameters during process sequence and to
adjust them. The adjusting possibility is especially useful in
start-up and optimization phase of new processes.

The process parameters are preset by variable contents in

integer or real variables (Ivar, Rvar). The ONLINE parameter
modification functions can adjust the contents of these two
variable types within presettable limits. For integer variables the
display and adjustment may additionally be limited to individual
parts of the variable.

3 Target group

Setter (level 2)

Programmer (level 3)

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4 Safety instructions

With the ONLINE parameter modification function it is generally

possible to modify the analog and digital outputs. Be especially
careful so that only the required modification will take place. An
operating error may cause extremely critical situations here, if
e.g. a gripper with a heavy load is opened and the load will fall
onto men or parts of the installation.

As long as the modification function is active (line marked

in blue in INFO_CNF) it is not possible to modify the robot
speed with the OVERRIDE button!

5 Conditions: Hardware
and Software

The functionality is already available in ROBOTstarV system

software from V3.0.

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6 Installation/Configuratio
n

This function requires no special installation, a functionable

sample application is included in the file ”INFO_CNF” in the
subdirectory ”S:/$CONFIG/$CNF” (as of version 5.0) or
”S:/$SYSTEM/$SYSCNF” (earlier than version 5.0).

In case the online modification function is to be activated by

pressing a key, corresponding MACROs are necessary.
Examples for this you can find in chapter 8 where programming
is described. These MACROs also have to be entered in the
corresponding CNF files (KEY_CNFx, MENUCNFx), also refer
to chapter 8.

7 Operation

Operation of the ONLINE modification function exclusively is

effected in the user program (UP) “INFO_CNF”. This program
has to be in the active window of the portable teach pendant
(PHG). The cursor is moved into the corresponding line.
Modification of this variable being released, this line will be
marked in blue. With the OVERRIDE button the value of the
variable can be modified now. The current value of the variable
will always be indicated.

As long as the modification function is active (line marked

in blue in INFO_CNF) it is not possible to modify the robot
speed with the OVERRIDE button!

The ONLINE modification function will be finished as soon as

you will quit the program “INFO_CNF”. It will be finished also if
the cursor is moved to a line that is not released for
modification.

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8 Programming

Programming of the variables to be displayed or to be modified

is exclusively effected in the AWP “INFO_CNF”. Further
programming may concern the files “KEY_CNFx”,
“MENUCNFx” and MACROs if the ONLINE parameter
modification is to be selected purposefully with pressing a key.

8.1 STRUCTURE DESCRIPTION OF THE

“INFO_CNF” FILE

The program “INFO_CNF” may be a main or a sub-program.

Beside comment steps only information steps (I-steps) are
admitted. The following description refers to the I-steps.

The information in “INFO_CNF” is table driven, therefore the

first I-step must include the tabulators “T” for separation into
columns. There must exist seven tabulators. These identify the
columns “Descriptor”, “Variable name”, “Format” (twice),
“OVERRIDE Factor (OF), “Minimum value” (MIN) and
“Maximum value” (MAX). Table 4 shows an extract from
“INFO_CNF”.

The distances of the tabulators may be freely selected, the

corresponding information, however, absolutely must be
exactly below the corresponding tabulator sign.

Under ”Descriptor“ or ”Descriptional Text” a freely selectable

text may be entered, which e.g. refers to the parameter. Like in
table 4 this may be a hint to the variable, it could also be a
process hint “welding current”.

The “variable name” or “Name of Var.” indicates which

variable is to be indicated and possibly to be modified. Here
integer and real variables, even individual array elements
hereof, are admitted, refer to example in table 2. A particularity
for integer variables is that the indication of the contents may be
limited to 1 to 32 successive bits, also refer to example in table
4. Doing so, the bits are numbered from 0 to 31.

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The column “Format” is subdivided. Here the type of numeral

representation of the variable contents (first column) as well as
the number of digits (second column) may be set. Admitted
identifications for numeral representations are G, g, E, e, R or r
for real variables, D, d, H, h, B or b for integer variables.

Information regarding number of digits is given in the x:y

representation, the significance of x and y varying depending on
numeral representation and even may be omitted.

Some possibilities are listed in the table 1 – 3 with examples

regarding indication.

Real variable illustrated by the number

12345.678987654321:

numeral number of digits examples

representation

R or r: significance of x: 12345.6789876543
floating point none, may be omitted.
representation All digits before the 1 12345.68
comma are always
indicated. x:3 12345.679

significance of :y: x:5 12345.67899

Number of digits
indicated after the x:1 12345.7
comma.
:3 12345.679

E or e: exponent significance of x: 1.234568e+04

representation none, may be omitted.
One digit before the x:3 1.234e+04
comma is always
indicated. x:8 1.23456790e+04

significance of :y: 2 1.23e+04

Number of digits
indicated after the
comma.

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G OR G: THE significance of x: 12345.7

SHORTER none, may be omitted.
REPRESENTATI Min. one digit before x:3 1.23e+04
ON OF the comma is
FLOATING indicated. x:8 12345.679
COMMA OR
significance of :y: 2 1.2e+04
EXPONENT
REPRESENTATI Number of digits that
ON WILL BE are indicated in total.
USED

Integer variable illustrated by the number 65535 (FFFFh):

numeral number of digits Examples

representation

D or d: significance of x: A 6 5 5 3 5
decimal space for min. x
representation digits in the output 2:y 6 5 5 3 5
will be reserved.
Always all digits are 7:y 6 5 5 3 5
indicated, but not a
leading “0”. 6 6 5 5 3 5

significance of :y:
none, indication may
be omitted.

H or h: significance of x and F F F F H
Hexadecimal y: A space for the
representation larger number of 4:2 F F F F H
digits in the output
will be reserved. If y 6:2 F F F F H
is bigger or equal to
x, then leading “0” 6:6 0 0 F F F F H
will also be indicated.
6 F F F F H

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B or b: binary significance of x and 00000000000000001111111111111111

representation y: the number of
digits of the bigger :2 11
indication will be
indicated In addition, x:20 00001111111111111111
the “0” is backed with
green, the “1” with 20 00001111111111111111
red.

In the column “OV-factor” the modification incrementation is set. It indicates which modification of the variable contents will result
if the OVERRIDE button is changed by one increment. The incrementation “0” or no indication in this column means that no
modification is possible. Thus a modification possibility can purposefully be blocked or released. Additionally applies that the
modification release is only given for valid I-steps.

In the columns “MIN” and “MAX” a minimum or maximum value may be given. ONLINE modification then is only possible within
these limits.

Table 5 shows the display mode of this INFO_CNF on the PHG. Instead of the indicated variable the contents of same will be
indicated. The programmed line from table 4 will only be visible during editing!

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C Decriptional Text Name of Var. Format OV-factor MIN MAX

I T T T T T T T

I analog output 1 _RANA_OUT[1] R 2:2 0.125 0.0 10.0

I analog output 2 _RANA_OUT[2] E :2 0.25 0.0 10.0

I binary output array 1 _IBIN_OUT[1] H 8:8

I binary output array 1 _IBIN_OUT[1],4 H 1

I binary output array 1 _IBIN_OUT[1],4-11 H 2:2 1

Table 4: Tabulator arrangement and examples from “INFO_CNF”

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C Decriptional Text Name of Var. Format OV-factor MIN MAX

I T T T T T T T

I analog output 1 2.5

I analog output 2 7.58e+01

I binary output array 1 000000A2h

I binary output array 1 0h

I binary output array 1 FEh

Table 5: Visible display of examples from table 4

The indications in the file “INFO_CNF” will be valuated during start-up of the RSV. New evaluation takes places after each editing
process so that newly introduced variables or formats will immediately be displayed.

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8.2 RETRANSCRIPTION OF MODIFIED

VARIABLE CONTENTS

The ONLINE modification will only modify the contents of the

variables, therefore this modification will be overwritten with
next COPY command of the sequence program. In the next
cycle the modification has to happen again.

Just in the optimization phase it is desired to take over

immediately into the sequence program the parameters that
were determined as optimum. For this purpose before the first
relevant COPY command the bit 0 is to be set in the system
variable _IPATH_MODE. This is best done with the command:

WRITE_BIT #VARIABLE, level: 1, Variable: _IPATH_MODE,

Bit_No: 0

in the sequence program or on key operation by a MACRO.

As long as this bit is set, the contents of the variable just

modified active will be retranscribed into the latest executed
COPY command in this variable. This is done with following
events:

• “INFO_CNF” is closed

• “INFO_CNF” no longer is the active window

• The cursor is set from the just modified I-step to another one

• A new COPY command for this variable will be executed

• for STOP on the path and change of operating mode

The retranscription is directly done into the latest known COPY

command if a digit constant exists there as source:

COPY source: 2.54, destination: _RANA_OUT[1]

A variable existing as source in the command, the modified

value will be written into this variable (after R_SOURCE):

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COPY source: R_SOURCE, destination: _RANA_OUT[1]

With the command

WRITE_BIT #VARIABLE, level: 0, Variable: _IPATH_MODE,

Bit_No: 0

the retranscription will be switched off again.

8.3 REQUEST OF MODIFICATION FUNCTION

PER MACRO

In this chapter you will find a complete AWP “INFO_CNF”,

some examples for suitable MACROs for direct selection of
variables to be modified as well as notes on modifications in the
corresponding RSV configuration files.

Especially regarding the adaptations in “AEND_SYS” we draw

your attention to the corresponding documentation. The
example shown here includes many MACROs that are not
indicated here since they have nothing to do with the ONLINE
parameter modification.

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8.3.1 MPR "INFO_CNF"

MPR "INFO_CNF"
C ***********************************************
C General parameter indication and
C ONLINE parameter modification
C ***********************************************
C With the ONLINE modification function
C real and integer variables can be changed.
C Only that variable can be modified where
C the cursor just is and which then
C is backed with a bar.
C ***********************************************
C Descriptional Name of Var Format OV-factor MIN MAX
text
I T T T T T T T
C -----------------------------------------------
C MAG welding CASTOLIN/FRONIUS
C -----------------------------------------------
I capacity _RANAOUT[1] R 2:2 0.0125 0.0 10.0
I ARC correction _RANAOUT[3] R 2:2 0.0125 0.0 10.0
I Pulse correction _RANAOUT[2] R 2:2 0.0125 0.0 10.0
C
I Oscillation R_P_AMPL R 2:2 0.0125 0.0 50.0
amplitude

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I Oscillation R_P_FREQ R 2:2 0.0125 0.0 10.0

frequency

C
C ***********************************************************************
C Now the determinations of the requested analog inputs follow:
C These cannot!! be modified
C ***********************************************************************
I Welding voltage _RANA_IN[1] R 2:2
I Welding current _RANA_IN[13] R 2:2
C ***********************************************************************
C Now the determination of random variables follow
C for example:
I Path correction _RANA_OUT[20] R 2:2 -0.01 -10.0 10.0
height
I Path correction _RANA_OUT[21] R 2:2 0.01 -10.0 10.0
side
C ***********************************************************************
END

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8.3.2 MAC "ONL_PULSCORR"

MAC "ONL_PULSCORR"
C
C Online modification of pulse correction
C
C #DefStart
C #D Name :ONL_PULSCORR
C #D MAC Vers.:1.3
C #D RSV Vers.:4.1
C #D RobAssist:MAG
C #D Date :31.03.1999
C #D author:Mr.Martin
C #D PLC :
C #D Parameter:
C #D Function :Online parameter modification
C #D :Analog output pulse correction
C #DefEnd
C
C
I ENDDEF
C
C Divide window
TAV_CNTRL Instr:"ctrl_siawin",Par:"HZTL"
C
C Switch Window
TAV_CNTRL Instr:"ctrl_siawin",Par:"CHWN"
C
SELECT_PROG
Name:"S:/$SYSTEM/$SYSCNF/INFO_CNF",Step:19
C
C Activate retranscription
COPY Source:3,Dest_Var:_ipath_mode
C
C END functions
TAV_CNTRL Instr:"return_wert",Par:"1"
END

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8.3.3 MAC "ONL_POWER"

MAC "ONL_POWER"
C Online modification of capacity
C
C #DefStart
C #D Name :ONL_POWER
C #D MAC Vers.:1.3
C #D RSV Vers.:4.1
C #D RobAssist:MAG
C #D Date :31.03.1999
C #D author:Mr.Martin
C #D PLC :
C #D Parameter:
C #D Function :Online parameter modification
C #D :Analog output capacity
C #DefEnd
C
I ENDDEF
C
C Divide window
TAV_CNTRL Instr:"ctrl_siawin",Par:"HZTL"
C
C Switch Window
TAV_CNTRL Instr:"ctrl_siawin",Par:"CHWN"
C
SELECT_PROG
Name:"S:/$SYSTEM/$SYSCNF/INFO_CNF",Step:17
C
C Activate retranscription
COPY Source:3,Dest_Var:_ipath_mode
C
C END functions
TAV_CNTRL Instr:"return_wert",Par:"1"
END

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8.3.4 MAC "ONL_ARCCORR"

MAC "ONL_ARCCORR"
C Setting of the arc length correction for
C power sources with synergy
C
C #DefStart
C #D Name :ONL_ARCCORR
C #D MAC Vers.:1.3
C #D RSV Vers.:4.1
C #D RobAssist:MAG
C #D Date :31.03.1999
C #D author:Mr.Martin
C #D PLC :
C #D Parameter:
C #D Function :Parameter setting
C #D :Arc length correction
C #DefEnd
C
I D Control voltage
I T Rlibo 0.0 10.0
C
I ENDDEF
C
LOC_VAR Name:Rlibo
C
COPY Source:Rlibo,Dest_Var:_RANA_OUT[3]
C
END

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8.3.5 MAC "ONL_EXIT"

MAC "ONL_EXIT"
C
C Cancel Online modification function
C
C #DefStart
C #D Name :ONL_EXIT
C #D MAC Vers.:1.3
C #D RSV Vers.:4.1
C #D RobAssist:MAG
C #D Date :31.03.1999
C #D author:Mr.Martin
C #D PLC :
C #D Parameter:
C #D Function :Online modification function
C #D :terminate
C #DefEnd
C
I ENDDEF
C
COPY source:_IACTWIN,Dest_Var:IEA
TEST #VARIABLE,Op_1:IEA,#=,Op_2:1,Label:"NO_CHANGE"
C
C Switch Window
TAV_CNTRL Instr:"ctrl_siawin",Par:"CHWN"
C
LABEL "NO_CHANGE"
C
C cancel window division
TAV_CNTRL Instr:"ctrl_siawin",Par:"OTLG"
C
C Deactivate retranscription
COPY Source:2,Dest_Var:_ipath_mode
C
C END functions
TAV_CNTRL Instr:"return_wert",Par:"1"
END

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8.3.6 MPR "CHNG_SYS"

MPR "CHNG_SYS"
C necessary modifications in system files
C
C SPR STARTBED
C insert as of step 4
C Initialization welding
U_PROG Name:"S:/MAC/WELD_INI"
C
C SYSCNF/CAN_CNF
C can be overwritten
C
C SYSCNF/INFO_CNF
C must be overwritten
C
C SYSCNF/KEY_CNF1
C insert step 34-35
I EDIT 01 T C 576 makroexec S:/MAC/WIRE,MAK
I EDIT 01 T C 578 makroexec
S:/MAC/W_OUT_WELDING,MAK
C
C SYSCNF/KEY_CNF2
C modify step 79-84
I EDIT 01 T C 576 makroexec S:/MAC/WIRE,MAK
I EDIT 01 T C 577
I EDIT 01 T C 578 makroexec
S:/MAC/W_OUT_WELDING,MAK
I EDIT 01 T C 579 show_menu S4,EINF
I EDIT 01 T C 580
I EDIT 01 T C 581 show_menu S6,EINF
C
C SYSCNF/KEY_CNF3
C modify step 73-79
I EDIT 01 T C 576 makroexec S:/MAC/WIRE,MAK
I EDIT 01 T C 577 show_menu S2,EINF
\I EDIT 01 T C 577 makroexec
S:/MAC/W_OUT_PARAMETER,MAK
I EDIT 01 T C 578 makroexec S:/MAC/
W_OUT_WELDING ,MAK
I EDIT 01 T C 579 show_menu S4,EINF
I EDIT 01 T C 580 show_menu S5,EINF
I EDIT 01 T C 581 show_menu S6,EINF
C
C SYSCNF/KEY_CNF5

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C modify step 80-86

I EDIT 01 T C 576 makroexec S:/MAC/WIRE,MAK
I EDIT 01 T C 577 show_menu S2,EINF
\I EDIT 01 T C 577 makroexec
S:/MAC/W_OUT_PARAMETER,MAK
I EDIT 01 T C 578 makroexec
S:/MAC/W_OUT_WELDING,MAK
I EDIT 01 T C 579 show_menu S4,EINF
I EDIT 01 T C 580 show_menu S5,EINF
I EDIT 01 T C 581 show_menu S6,EINF
C
C SYSCNF/MENU_CNF2
C insert step 25-32
I S1 01 1 M WIRE
I S4 01 1 M X ONL_POWER
I S4 01 2 M X ONL_PULSCORR
I S4 01 3 M X ONL_ARCCORR
I S4 01 6 M X ONL_EXIT
I S6 01 4 M X ONL_O_AMPL
I S6 01 5 M X ONL_O_FREQ
I S6 01 6 M X ONL_EXIT
C
C SYSCNF/MENU_CNF3
C insert step 25-47
I S1 01 1 M WIRE
I S2 01 1 M FILLET
I S2 01 2 M BUTT
I S2 01 3 M LAP
I S2 01 6 M CRATER
I S4 01 1 M X ONL_POWER
I S4 01 2 M X ONL_PULSCORR
I S4 01 3 M X ONL_ARCCORR
I S4 01 6 M X ONL_EXIT
I S5 01 1 M SEARCH_ON
I S5 01 2 M SENSOR
I S5 01 3 M ARC_SENSOR
I S5 02 1 M PATHINIT
I S5 02 3 M X ONL_HIGHT
I S5 02 4 M X ONL_SIDE
I S5 02 6 M X ONL_EXIT
I S6 01 1 M OSCILATION
I S6 01 2 M OSC_PATTERN
I S6 01 3 M OSC_ANGLE
I S6 01 4 M X ONL_O_AMPL
I S6 01 5 M X ONL_O_FREQ
I S6 01 6 M X ONL_EXIT

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C
END

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8.4 GENERAL NOTES

• As a matter of principle make careful use only of the

possibility to adjust (binary) outputs; high danger of personal
injuries or material damage. For trouble shooting or for
commissioning of the installation this on the contrary may be
useful for determination of faulty outputs (wiring faults,
defective output, etc). Take suitable safety measures to
avoid personal injuries or material damage!

• Equivalent is applicable for automatic retransription of

modified variable contents. Take care to avoid

• * modifications by mistake

• * modifications by mistake not to overwrite optimum

parameters

• Selecting the variables to be modified sparing use should be

made of user variables. Since same might shift in the
memory, a new search for the corresponding variables as a
result will be necessary. This search may extend the
reaction time of these variables.

9 Application Software

For different application purposes MACROs are available.

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10 Error Messages/ Debugging

10.1 ERROR MESSAGES

Prefix Error no. Description of fault Cause Remedy

S 111 Programming error 10001 The program does not exist or Generate program or put into
is in an other subdirectory right directory
”Program ”INFO_CNF” not
found”

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11 Glossary

Letter Term Explanation

A AWP user program

M MAX maximum value, maximum

MIN minimum value, minimum

O OV OVERRIDE factor

P PHG portable teach pendant

12 Index

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