操作手册bos6000相关软件培训

1、BOS 6000培训资料Written by:-BRC内容定义 PSI6X00.标定工具器参考列表器状态编程窗口 焊接程序 扩展焊接程序热量递增设置电极设置.L1Pg 4Pg 15Pg 18Pg 19Pg 21Pg 23Pg 38Pg 39Pg 41Pg 45内容标定 电流标定 模拟运行 功率模块设置Pg 49Pg 56Pg 66Pg 67Pg 68Pg 73结束语PSX.6PST:交流.L1/W1器/PSI:中频器6:6500,6200,6300,6100功率不同1236:并联的I/O:Profibus I/O:Interbus I/O:Device Net:的版本L1:空冷,400Volt

2、W1:,400Volt奔驰项目的硬件接线图FAW B6项目的硬件接线图带总线的接线图举例汽车项目我们都采用第四种电源接法,但具体的定义还根据项目的情况Contents内容Device configuration PSI6300.114/155L1 Konfiguration tool定义的工具定义Timer ReferenceTimer status器的参考表器的状态ProgramIcons编程框Weld Sequence 焊接程序Extended weld Sequence扩展程序Heat StepperGeneral Set-up热量递增通用设置Electrode set-up电极设置Co

3、ntents内容Force Calibration Routine标定Current Calibration routine电流标定Simulate Start模拟启动Power unit set-up电源设置DiagnosticsBacking up the timer parameters备份Restoring parameters to the timer恢复数据Single Point Lesson (SPL)第一部分项目/Bosch Rexroth 焊接器A1 PSI6300.L1 Bosch Rexroth 焊接器 (timer)Top ViewSide ViewKonfigura

4、tion Tool定义工具 The purpose of the configuration tool is for the user to be able toalise the BOS 6000 operating software, for example, to manipulate the text within the screens, set backup paths, hide unused input or output channels, suppress unwanted error messages用于的一些设置 For the password to access t

5、his area, see your Welding engineer只有工程师知道Konfiguration Tool定义工具 To add a new user group.增加用户组 Right click on the “User group window,and atext box should appear, select add user group In the next text box, enter your new user group and add the user level增加新的用户和用户等级Your new group will be automaticall

6、y saved, when you exit the konfig tool新用户可以自动 To add a new user in an existing user group. Right click on the “Users window, and a text box should appear, select add user Add the new user name增加新的用户名Insert your new password添加Confirm your password确认 Select the user Group选择用户定义Username + Password用户名+T

7、imer reference器列表Add the timer name器名Add any reference comment select your comm Channelthis is your software 通讯方式communication method V24, Ethernet.etcIf you are connecting via Ethernet, then insert the IP address here添加地址Select Online or Offline modeSelect the direction of data flow, on initial com

8、municationWhen the information has been installed, press ok, then select the Continue button to access the program data下一步To add a new or additional timer, select the Add button first, the Add/change Timer box will then appear above增加器Timer Status器状态Monitor the Status and Description window, if a re

9、d bar appears and stays then there is a problem with your communication path, cable, or thetimer may be off.通讯状态,如果颜色是红色,那么请检查相关连接硬件Monitor the Status and Description window, a yellow bar should proceed a green bar. 黄色代表在通讯中,如果转变为绿色,代表完全通讯上This indicates that communication path is operational, and t

10、he database is being populated with the timer information. 数据在对比交换Please be patient, on the initial start- up it can take up to 5 minutes to gather all the data for the database.All subsequent connections will only take seconds to get on-lineProgram PageThe spot number, program and communication sta

11、tus is found at the top of program page, as wellas the drop down据和通讯状态s焊点数The raised tab indicates the page that is currently being viewed目前可以显示的菜单All functions/pages can be quickly accessed via the “icons” that are situated at the top of the pages. 快速进入其他功能菜单A single click will select the required

12、page, and another single click will return you to your previous screen.每个功能块可以单独进入/Icons功能块Plant layout工厂Protocol数据库Error Table错误状态Compare比较Pre-warningTable预警ParameterOverview参数预览Login进入Spot referenceComments焊点注释Rights Administration权限TimerReference列表器Overview总预览Spot referenceTable焊点列表Program Page编程

13、(Parameter data)Correction调整Diagnosis(i/o interface)Set-up设置Programtabs编程菜单By selecting individual tabs within the pages you can navigate around the software at the click of a button子编程菜单Dependent on the timer status, you can see if the timer is online, or offline.器的通讯状态Blue is working offline Green

14、 is working onlineYou can also see at a glance if the weld has a pre- heat, a post heat, or even if upslope or down slope.焊接参数的设置情况Sequence编程ProgramThe sequence screen allows the user to see the critical weld parameters at a glance编程的参数PressureWeld timeCurrentHoldSqueezeConversion from cycles to mil

15、liseconds.时间转换5 cycles = 100mSI.e. multiply by 20 to convert Cycles to millisecondsOr divide by 20 to convert milliseconds to cyclesSequenceTo select a weld program:- to access the required program, simply select the program from the up/down buttons, or type in the actual program number. The electro

16、de number will update when a program is selected.To selepot number:-utilising the down arrow select the required spot number, and the program that is associated with it will automatically appearInhibit Seq (P) (Inhibit this program sequence)阻止启动This needs to be set to “Off”, if not then the weld seq

17、uence will be inhibited for this program onlyWeld On/Off Int (P) (Internal weld on/off) 焊接/调整This needs to be set to On, if notthen the weld will be turned Off for this program onlySequence:- There are 3 sequence options, Single:单点 1 weld sequence per start signalRepeat:1 weld sequence repeated unti

18、lthe start signal is droppedSeam:缝焊 1 weld permanently on till the start signal is droppedSequenceMonitoring:- Mix or Standard混合/标准Standard mode: the actual current is determined by the complete weld cycle including any cool timesMix mode: the actual current is determined by the individual weld time

19、s*see illustration on the next sheet下个菜单Sequence程序Sequence程序Regulation:- Mix or Standard调整模式-混合/标准If mix is selected, weld 1 & weld 3 can be programmed in PHA (phase angle) or KSR (constantIf standard is selected then weld 1 and weld 3 can only be programmed in the same mode as weld 2current) modeSe

20、quencePHA: Phase Angle Regulation热量调整Programmed in scale units %The greater the %Ht, then the greater %age of current flowing31130 - Electricaldegrees0180 120990-15- Scale units (%)High currentProgrammable rangeLow currentHalf-cycle of mains voltagePhase angle, fixed value determined by programSeque

21、nceKSR: Constant Current Regulation恒流模式Programmed in Kilo Amperes (kA)The current measuring device (Toroid) determines the actual currentThis is compared to thed valueThe timer can then adjust the phase angle ( ifrequired )so that thed value can be achievedModes: primryregulation or secundaryregulat

22、ionSequence程序Electrode:-电极0 3 different electrodes can be selected 0-3可以选择Reweld:-重新焊接If this function iivated and alow weld current occurs with the start signal still high, the control will automatically attempt toreweld the program, if the weld is low again a weld fault is output.Note:- if there i

23、s no current, then a reweld will not be activatedSequence程序Impulse:-脉冲循环数This function indicates how many times the weld 2, cool 2 function is repeated during 1 weld sequence.焊接.2的循环次数If the impulse function has a figure greater than 1, then the portion of the program that is inside the yellow shape

24、 is repeated however many times is programmedSequence程序The time monitoring enables the weld time to be monitored and limits can be set to ensure that if the weld time is greater than or lower than the set limits, an error is produced 时间设置SequenceAs with many functions within the BOS6000 software, if

25、 a function is not programmed, the window may not be visible,窗口显示e.g. if the impulse is at 1,then the COOL 2 time is not visible.SequenceHowever, if the impulse were increased to a number greater than 1,then the cool 2 time becomes visibleThe same can be said for the monitoring and regulation parame

26、tersWith the kA Monit set to Off, no extra parameters are visible.SequenceWhen the monitoring iivated,all the tolerance band parameters become visible电流可以看见了Sequence 程序1234Repeat factor, is the number of consecutive welds allowed between the conditional tolerance band and the lower tolerance band重复系

27、数4231SequenceRef, kA is the programmed reference current参考电流Act. Ref. kA is the actual current achieved实际电流Average PHA is the actual Phase angle required to achieve the required current平均导通角Extended Sequence扩展程序from this page the pressure profile function can be activated.设置When the profile iivated

28、the forcecan be programmed to a specific value at any time during the weld sequence.The force can be altered up to 10times during the weld process每次焊接过程可以设置10个值和时间Please note, as with all parameters, if the cursor is placed in a programmable area, upper and lower limits of the selected parameter wil

29、l appear at the base of the screen显示编程范围Heat Stepper热量递增Heat increase% between tip dresses热量递增Max Wear:-The number of welds over which the heat is stepped (incremented)Heat Stepper热量递增Heat increase% between tip dresses热量递增Tip Dress Steps:- The number of dress steps (10)Dress-Request:-The number of w

30、elds before the max wear that the tip dress request output iivatedHeat stepper:- activation on/offWear factor:- individual welds can be given a greater or lesser “weighting”, dependent on the actual wear to the tipsWear/comp:- The number of welds taken to complete one cycleMax Wear:-Warn Wear:- Numb

31、er of welds before the end of the max-life, that pre-warning becomeive (50)i.e. 5450 weldsThe number of welds over which the heat is stepped (incremented) (500)Please note:-注意The Max life is calculated by the multiplying (Max Wear x tip dress steps) + Max Weari.e. (500 x 10) + 500 = 5500 weldsDress

32、new Electrode:- The weld is inhibited, until the gun is dressed, immediately after the electrode has been replacedGeneral set-up设置If activated the weld will be inhibited when max life is reached电极更换前停止焊接Mode Pressure Output:模式There are several options for pressure output, 4-20mA, 0- 20mA, this proje

33、ct requires 0-10V output to the prop valveThe (S) indicates that the function will be activated for ALL programs阻止所有程序Max Weld Time, this is the control of the max weld time, for all programs, normally 0 2000mS, but here set to 600mSThis parameterInhibits the current Monitoring on All programsMax Re

34、welds:- this the number of consecutive welds allowed that are inside the conditional tolerance band重焊次数General set-up通用设置If activated the weld will be inhibited when max life is reachedMode Pressure Output:There are several options for pressure output, 4-20mA, 0- 20mA, this project requires 0-10V ou

35、tput to the prop valveA measuring loop check is a verification ofThe (S) indicates that the function will be activated for ALL programsMax Weld Time, this is the control of the max weld time, for all programs, normally 0 2000mS, but here set to 600mSthe currensor in the secondary circuit.On : Measur

36、ing loop test active, sensor faults are detected.Off : Measuring loop test not active, sensor faults are not detected.This parameter Inhibits the current Monitoring on All programsMax Rewelds:- this the number of consecutive welds allowed that are inside the conditional tolerance bandGeneral set-upI

37、f activated the weld will be inhibited when max life is reachedMode Pressure Output:There are several options for pressure output, 4-20mA, 0- 20mA, this project requires 0-10V output to the prop valveA measuring loop check is a verification ofThe (S) indicates that the function will be activated for

38、 ALL programsMax Weld Time, this is the control of the max weld time, for all programs, normally 0 2000mS, but here set to 600mSthe currensor in the secondary circuit.On : Measuring loop test active, sensor faults are detected.Off : Measuring loop test not active, sensor faults are not detected.This

39、 parameter Inhibits the current Monitoring on All programsMax Rewelds:- this the number of consecutive welds allowed that are inside the conditional tolerance bandCurrent measurement selects the type of monitoring, either secondary or primaryGeneral set-up通用设置The Fade out time parameter is used to s

40、uppress the natural current rise at the beginning of the weld time for current measurementThe Trail current parameter is used to activate or deactivate measurement of the trail current after the last weld time.On : The trail current is included in the measured result.Off : The trail current is not i

41、ncluded in the measured result.The trail current must match the settings of the external current meter for comparative measurements.Electrode Set-up电极设置The %I Prewarning parameter indicates the heat value (in scale divisions SKT) for which an imminent %I limitation is to be detected for the electrod

42、e displayed.Upper currrent limit is theum programmable set limit of the current in the individual electrodeBosch sensors have been adjusted to 150 mV / kA. When using third- party sensors, the appropriate transmission ratio can be programmed using the Toroid sensitivity parameterthe reference curren

43、sor canbe programmed using the Toroid sensitivity 2 parameter.Fors on themeasuring range, see the next sheetElectrode Set-upElectrode Set-up电极设置Transformer type. For this project we are using an ARO 56kVA, other transformer can be selected. This automatically selects the transformer ratio, and the d

44、iode typeThe Diode supervision/monitoring parameter may be used to deactivate diode monitoring (secondary diodes of the welding transformer).The computational emulation of the welding diode temperature determines whether the junction temperature is rising to more than 150C, the switch off temp can b

45、e programmed from this parameterActual welding diode tempActual Mains supply VoltageElectrode Set-up电极设置For the calibration procedure see SPL How to calibrate theForce and Current on a bosch L359 Welding ControlSingle Point Lesson (SPL)第二部分项目 /Force Calibration For Welding GunsPlease select the corr

46、ect timer,from the drop down制器Select the calibration routines which can be located on the Electrode Page标定Ensure that the Transformer Type,Heat Level Warning and Upper current limit are set as shown电流选择控To access Force Calibration for either Gun 1 or Gun2, Press the Force Calibration KeyForce Calibr

47、ation For Welding GunsType here the upperand lower pressure limits for the calibration routine ( As a rule the upper limit should be 2x the value of the lower limit) The lower limit should be set to around 20% to allow for accurate pressure around the area used for the Dress Routine (61,62 and 161,1

48、62).Select here the Program you wish to use for the calibration routine. You should select a program that is associated with the relevant electrode you wish to calibrateThe KN display is only used with Servo Guns. There are none of these on the L359 ProjectIf you want to change the values, place a t

49、ick in the box before you type in the new values. The changes will then be stored for the next time the routine is entered. Press the OK button to enter the next screenForce Calibration For Welding GunsAs this screen appears you should hear theParker proportional valve either pressurise or exhaust t

50、o the upper limit value set in the previous screen. You should nowmanuallythe Gunonto the force meter.Enter thevalue intothe upper box. To proceed press Enter on your PC this enters the upper limit actual value into the timerForce Calibration For Welding Guns As Enter is pressed you should hear the

51、Parker Proportional valve exhaust to the lower limit set on the previous screen. Againthe Gun onto the force meter.Enter thevalue into thelower box and press the Enter key on your PCThis enters the lower limit actual value into the timer As a rule the upper value is 2x the lower value As the OK butt

52、on is pressed an information point appears showing the value of the now calibrated Max. Pressure. Press OK to Accept this As the OK button is pressed an information point is displayed. Press OK to accept this.Force Calibration For Welding GunsYou should now return to theSequence page andtheGun on th

53、e force meter to test theProgrammed Pressure set in the Base Pressure Value.Please note:- check the I/O page to see which programis being activated by the robot.The pressure in this program Will be output to the prop valve.JLR standard tolerance is0.2 of Programmed ValueForce Calibration For Welding

54、 GunsThe calibration routine has set the figures shown .If after adjustment the measured values are found to be out of range another Force Calibration routine should be carried out.Single Point Lesson (SPL)第三部分Current Calibration For Welding Guns电流标定Current Calibration For Welding GunsPreparationEns

55、ure that the following settings areIn teral Tab theCurrent MeasurementMode should be set to.Secondary Regulation.Current Calibration For Welding GunsSelect the calibration routines which can be located on the Electrode PageEnsure that the Transformer Type,Heat Level Warning and Upper current limit are set as shownEnsure that the Diodes settings are as followsEnsure that the calibration figures are 150mV +/- 20mVTo access Current Scaling for either Gun 1 or Gun2, Press the Current Scaling KeyCurrent Calibration For Welding GunsType here the upperand lowe