8.7 Bending process
1 Prepare related components and connecting wires
1.1 Prepare related components
1 grating ruler pulse frequency divider, 1 HUACHENG system mainboard with ABZ port, 1 power supply unit with DC5V output, 2 tool calibration levers, 1 photoelectric sensor switch. Others (if any) will be supplemented:
* Link of grating ruler pulse frequency divider: https://item.taobao.com/item.htm?spm{{0}}a1z10.1-c.w4004-22518123948.41.22887311lQ0qB6&id=597924780399
* HUACHENG system mainboard with ABZ port (Specification: ES2A MC V1.2) needs to bought by contacting BORUNTE
* For power supply unit DC5V output, use DC5V power in robot ABZ port directly, or use external power (standby)
* Tool calibration lever should be prepared by yourself, and should be installed in the center at the end of the robot; the end of the tool should be a conical tip
* Photoelectric sensor switch should be prepared by yourself according to the on-site situation and should be attached with an inductive iron sheet
1.2 Definitions and connections
Bending machine IO definition and circuit diagram, robot IO definition and circuit diagram (robot IO definition table, electrical diagram of connection between robot and bending machine)
The above is for reference only. For details, please refer to corresponding bending machine operation manual
* Please refer to the related definitions and descriptions to correctly connect the interactive signal between robot system and bending machine system.
* No other annex available
2 Software opening and loading steps
2.1 Software opening and loading steps
Power on the robot control system, enter the robot control system, open and load the software as per the following:
① Login (Remark: Open the Login page)
② User (Remark: Select "Manufacturer Technician" in User)
③ Password (Remark: enter "brtbrt" in the password box)
④ Login in (Remark: Click "Login in")
⑤ Settings (Remark: Click "Settings" when the robot system is in the stop mode)
⑥ Product Settings (Remark: Select "Product Settings")
⑦ craft Setting (Remark: Click "craft Setting")
⑧ Technology type (Remark: After selecting "BendingProcess", the robot will save automatically and pop up the bending process box at the bottom to proceed to the next step)
⑨ Some technology takes effect after rebooting (Remark: After selecting BendingProcess, power off and restart the control system so that it takes effect; after rebooting, if the comments X20, X21, X22, Y20 on the IO monitoring function bar are displayed in accordance with the bending process IO definition table, it indicates that the bending software is loaded successfully so that it can be normally used and bending process parameters can be set)
3.1Bendingfilenumberdefinitionexplanation
①Bending File Number:After setting the bending file number (0-49),the system stores various bending parameter sand bending table coordinates.
②Description:Savedwiththecurrenttechnologyfilenumberforuser'scustomnaming
③point(logpoints):Fromtoptobottom,therearelogpointsP1andP2,whichrespectivelylogthepositionsofthetwo robotscorrespondingtothepositionsofthetwogratingrulers,convenienttocalculatetheproportionalrelationofthe gratingrulerafterstorage;thecalculatedvalueneedstobemanuallyfilledin"gratconstradio";thenclick"save"tobe effective ④gratconstradio:Thisparameterandthecalculatedvaluedonotaffecteachother;thecalculatedvalueisforreference,whilethisparameterneedstobemanuallymodifiedunderthemanufacturer'sright;duringfollowing,therobotwill automaticallycallthegratconstradio.
⑤status:ThelogstatusoflogpointsP1,P2;greenforlogsuccess,greyforlogfailure
⑥linearencoder(gratingruler):DisplayofexternalgratingrulerdatareadbyrobotthroughABZ
⑦CoorSeclect:theworkbenchcoordinatesIDusedforthecurrenttechnologyfilenumber
⑧useExternSensor:use/unUse,respectivelycorrespondingtotwomodesofbendingprocessusedbytherobot,namely followbendingandfixedspeedbending
⑨Lower Die V groove width:angle of Vgroove of bending machine(unit:mm)
⑩Sheet thickness :sheet thickness of bending workpiece(unit:mm)
⑪V groove deep:V groove depth of bending machine(unit:mm)
⑫Rad: Bending angle of product;after setting,corresponding to the follow bending angle of robot. Follow bending angle of robot=currently set value divided by 2 (the directly set value is equal to the angle value followed by the robot) *(Itcanbesetforexternalsensorusedbyfixedspeedbending) ⑬speed:Thespeedoftherobot'sfollowingthebendingcutterduringbending(unit:mm/s) (*Itcanbesetforexternalsensorusedbyfixedspeedbending) ⑭Acceleratedspeedtime:Thetimefortherobottoacceleratetothebendingspeedwhenthebendingmachineis performingbending(unit:ms) (*Itcanbesetforexternalsensorusedbyfixedspeedbending) ⑮DelayDistance:Afterthesystemdetectsthebendingstartsignal,delaythisdistancebeforefollow(unit:mm) (*Itcanbesetforexternalsensorusedbyfixedspeedbending) ⑯GlideDistance:Thedistancebywhichtherobotmovestheworkpiecedownafterthesystemreceivesthesignalthat thebendingmachinehasstartedandbeginstomovedown,onlyeffectivewhentherobotbendsagainfollowingthe bendingcutter'sleveling(unit:mm)
⑰GlideSpeed:Thespeedatwhichtherobotmovesdowntothebendingpoint(unit:mm/s)
⑱GlideAcceleratedspeedtime:Theacceleratedspeedatwhichtherobotmovesdowntothebendingpoint(unit:ms) ⑲GlideDelayDistance:Thedistancetherobotwaitsforthebendingcuttertoglidebeforetakingaction(unit:mm)
⑳font_pos:The time that take seffect after running the "delaytime" in the follow command.(The delaytime is the filtering time after the pressurization signalis effective)When the distance calculation after this time reaches the set value of the front distance,the robot begins to bend.
㉑Return Accelerated Speedtime:The time required for the robot to accelerate to the set return speed(unit:ms)
㉒Return Delay Distance:After the bending is finished, the bending cutter moves up to reach the return delay distance before the robot moves up(unit:mm)
㉓Die Corner:According to on-site bending cutter setting,if set to 0,it indicates that the bending cutter has noc orner (unit:mm)
㉔MoveType:0-Down:the bending cutter moves down;1-Up:the cutter groove moves up
㉕leveling Speed:The speed at which the robot returns to its pre-bending pose(unit:mm/s)
㉖leveling Accelerated speedtime:The time for the robot to accelerate to the leveling speed during leveling(unit:ms)
㉗Return Distance:The distance the robot follows the bending cutter's moving up after bending(unit:mm)
㉘Return speed:The speed at whichthe robot follows the bending cutter's moving up(unit:mm/s)
3.2Bendingprocesscommandanddefinitionexplanation
① Bend Cmd - BENDTRACK: Execute follow action immediately after receiving the pressurization signal, and end follow action immediately after receiving the bending end signal Bend Cmd - BENDFLATBACK: The robot returns to its pose before bending Bend Cmd - bend return: Execute an up/down movement following the bending cutter immediately after receiving the bending end signal ② Use Bending File Number: The set range is 0-49. Call the bending file number stored on the craft Setting page
③ Description: The annotation text in each technology file number
④ IOCheckTime: X20 bending pressurization detection time, with alarm to be sent if no signal is detected after the set time (unit: mm)
⑤ delayTime: After the pressurization signal is effective, perform delayed bending follow; this parameter is delay time; data generated during this set period will be discarded without recording. (unit: ms)
⑥ collaboration Setting: unUse/use. If the collaboration axis is not used, there is no action effect; if the collaboration axis is used, select the axis object and number to coordinate with; after setting, collaboration axis has corresponding coordination action of set axis in the follow process, being able to reach the set running position of M7/M8.
⑦ filter_x/y/z/u/v/w (fixed compensation): after filling in, the robot will start to perform equal-proportion compensation after it starts bending follow action until the compensation is finished at the running end.
⑧ acc_cycle: Time of acceleration for following the bending path from the beginning of the action to the start point (unit: ms)
⑨ dec_cycle: Time of acceleration for following the bending path to the end point (unit: ms)
4 Use flow
1. After the robot is fitted with the tool calibration lever, create new tool coordinates, select "TwentyTree Point..." for "Tool Type Sel" as shown in the image below, and refer to Twenty-three-point tool calibration in Welding Process Specification for the setting method and steps. After setting, ensure that the tool accuracy is less than 2mm, and the maximum error of rotation around the tool is less than 3mm. Do not store 23 points with Axis7 joint coordinates in the command when create a module number.
2. Data communication confirmation of grating ruler of bending machine: Confirm that the display data of 997 is displayed normally at the pressurization point of the bending machine and the return-in-place point of the bending machine, as shown in the image below. Note: If both positions are 0, the machine cannot be used normally, and the connection should be inspected.
6. Calibrate "workbench" on the bending machine with tool; in manual mode, click workbench calibration, and then click "new" for workbench setting. (Remark: No workbench, only tool)
3.1 The workbench direction on the bending machine is defined: origin P0 is the pressurization point at which the product is pressed just above the bending cutter groove; PX is the point starting from the pressurization point and parallel to the bending cutter groove; PY is the point perpendicular to the line from P0 to PX.
（3）P0 is origin of coordinate axes; PX is any point in the coordinate axis X direction; PY is any point in the coordinate axis Y direction, as shown in Figure 3-1 below.
（4）P0 position is the pressurization point of the bending cutter, namely the position where the product surface is pressed by the lower part of the bending cutter of the bending machine. The thicker the product, the higher P0. PZ is the point parallel to P0 and away from the direction of the bending machine. PY is the point perpendicular to the upward direction of the line from P0 to PZ, as shown in Figure 3-2 below.
Note
*1 The pressurization point need to be strictly positioned
*2 Confirm the position of grating ruler when pressing down; when testing the pressurization point, first modify the gliding speed into manual or minimum
*3 It is ok to calibrate the workbench with or without collaboration table. If used, it is necessary to ensure high accuracy of collaboration axis; otherwise, the calibration will be abnormal
For example, the bending cutter of the bending machine moves down. The specific steps are as follows:
① Confirm that the outer width of the bending cutter is measured to be 10mm and the pressing-down position of the pressurization point is 5mm in the middle of the cutter groove.
The product needing to be bent is {{0}}.7mm think metal sheet. First adjust the sliding block of the bending machine to stick to the outer surface of the cutter groove, then place the product or a product of the same thickness evenly above the bending cutter groove and make it against the sliding block. At this time, draw 1 horizontal line 5mm from the edge of the product, and finally record the grating scale data displayed by 997 address data when the bending butter touches the product surface (most of bending machine signal is given 3mm in advance, so please record the actual position of the pressurization point, and observe whether the running of the robot is synchronous). Lift the bending cutter to the highest, manually hold up the plate, and align the position of the robot with the tool calibration lever plus world coordinates at the horizontal line drawn on the product. It is recommended to find a fixed reference at the bottom of the plate and define it as the bending machine origin P0. Then move some distance to the left in the direction of the horizontal line, and define it as P0X. Then run back to origin, and on this basis, draw a perpendicular line based on the above horizontal line; move up the perpendicular line and define it as P0Y.Bending machine workbench definition is finished. Bending machine workbench definition is finished. Remark: Detailed explanation of steps: ① The outer width of the cutter groove is measured to be 10mm, and its center point is 5mm away; use the product or a metal sheet of the same thickness, hold the stopper against the cutter groove, and hold the metal sheet against the stopper, parallel to the cutter groove, laid flat on the cutter groove, draw a horizontal line parallel to the cutter groove in the position 5mm away from the edge of the metal sheet, select any point on the horizontal line of the metal sheet as P0, define a point on the horizontal line after P0 moves some distance in the direction of the cutter groove as P0X, and define a point after P0 moves up some distance in the perpendicular direction as P0Y
7. Linear collaboration table calibration with tool (Remark: No workbench, only tool)
*Note: If there is no collaboration table, skip this step and proceed to the next step
4.1 Enter extended axis calibration workbench page (select ground rack, tick enable, and restart), correspond to the current line, fill in as described, set 3 points, which are aligned at the same position. The selection tendency of points is to increase or decrease in the same direction. It is recommended to select the running distance of the point as far as possible. However, it must be at a reasonable arm span of the robot. During the calibration of 3 points, the robot cannot change its pose. The calibration result should not be greater than the maximum rotation error of the robot tool. It is recommended to manually test the farthest range and distance at the same target point, and finally click "save" for finishing.
*Note: Generally, if the running plus direction of J7 axis is same as the X plus direction, the direction is correct. Among motor parameters, J7 reduction ratio must be filled in as per the actual value; "lead" is the actual distance per revolution of the robot. To ensure accuracy, 10 or more circles are recommended. Actual running distance measured (mm) ÷ number of currently run circles = distance per revolution (mm). After filling in, give 2 large absolute position distances, and inspect whether the error is reasonable. If the error is greater than 3mm, the lead should be reset; otherwise, the effect of bending process will be affected.
5. Switch to using the robot sucker tool. Setting method: Create new tool coordinates with 2-point method, make the robot return to the origin and set in the current point, set the deviation direction Z value, click "count", "modify" and "save" to finish the creation. After creation, directly use the tool with workbench and collaboration table
8. 1. Test effect: Fill in the bending process parameters "Die V groove width", "Sheet thickness" and "V groove deep" on the "craft Setting" page according to the actual situation of the bending machine, move the robot near the pressurization point of the product, perform dry running to predicate whether the running track, direction and accuracy of the tested robot are correct, then perform formal instructional operation, to avoid hidden safety hazards.
5 Instruction example mold program
The example is to instruct automatic bending follow, feeding & blanking and pick & placing of metal sheet box shell products needing to be bent seven times by moving down the bending cutter of the bending machine
*AnnexI. Common Problem Solving Measures
①Pressurizationpointbendingfollow:trackplanningfailure,J6over-speed,singularpointalarm,andsoon.Because theposeisnearthesingularpointoftherobot,theposeofthepressurizationpointoftherobotneedstobechangedto beyondthesingularpointrange ②Jitterduringpressurizationpointbendingfollow.Inthiscase,youcanobservewhetherthestructuralpositionis reasonable;ifunreasonable,pleaseadjust theM7axispositionoftherobot;shorteningthemovingdistanceofM7canoptimizetheproblem. ③Jitterduringstartingandendingofpressurizationpointbendingfollow.Inthiscase,theaccelerationcycletime,decelerationcycletime,delaytimeandotherparameterscanbeincreasedtooptimizetheproblem ④Followexcessivedeviationofbentproductposition,whichleadstodisqualification.Inthiscase,pleasefirstobserve whethertheabsoluteaccuracyoftherobotmeetstherequirementsandwhetherthemechanicalpositionoftherobothas anydeviationcausedbyoriginsliding.Ifitisafixeddeviation,youcansetthecurrentfixedcompensationfollowingthe bendingcommandtocorrectthedeviationsothattheproblemcanbesolved ⑤Followexcessivedeviationofbentproductangle,whichleadstodisqualification.Inthiscase,generally,thebending workbenchestablishedbytherobotonthebendingmachinehasaproblem.Youcanreinspecttheaccuracyofthe workbenchormodifythecurrentlyboundworkbenchorigin,tooptimizetheproblem. ⑥Aftermanualuseoftheprogramforbending,thebentproductangleshouldbeequalto90 degree ,canbeslightlymorethan 90 degree ,whichismanuallyadjustable,butcannotbelessthan90 degree ,whichismanuallynonadjustable. ⑦Thebendingmachinepressurizationstartpointcorrespondstotherobotpressurizationpoint,andthebending machinepressurizationendpointcorrespondingtotherobotbendingfollowendpoint. ⑧Thequalityoftheproductisidentifiedtobegoodorbad:①bendingangleassurance②bendinglengthassurance ⑨Theinfluenceofjigsontheproductmainlyliesinthattherobotmustbelaidflatandconsistenteverytimeafter movingtothepressurizationpoint.Thefirstelementofmanualplacementistobelaidflatagainstthestopper. ⑩Bendingmachinesafetyparameterconsiderations,andsoftwarelimitations(whenexecutingabendingfollow command,itmustbeabletosetwaitingforacertaintimeofpressurizationdetectionIObeforestartingtheaction;if beyondthetime,alarmwillbegiven.andsoon.)