Integration Guide For The Fanuc RARN SABB Application v1.0

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Contents
1. Applicative screen......................................................................................................................................... 4
1.1 Main screen ........................................................................................................................................... 4
1.2 CALIBRATION screen ............................................................................................................................. 6
1.3 MANUAL TEST screen ............................................................................................................................ 8
1.4 SERVICES screen .................................................................................................................................... 9
1.5 DEBUGGING OFFSET screen ................................................................................................................ 11
2. How to do the calibration ........................................................................................................................... 13
3. How to use the test mode .......................................................................................................................... 14
4. Routines ...................................................................................................................................................... 15
4.1 RH_OFFS ................................................................................................................................................... 15
4.2 RH_PRESS ................................................................................................................................................. 16
4.3 RH_SERV ................................................................................................................................................... 16
4.4 RH_CLEAN ................................................................................................................................................ 17
5. Programs ..................................................................................................................................................... 18
5.1 RH_PROC_TP ............................................................................................................................................ 18
5.2 RH_SERV_TP ............................................................................................................................................. 19
5.3 RH_CLEAN_TP .......................................................................................................................................... 19
6. Inputs/Outputs, Registers, Position registers............................................................................................. 20
6.1 Inputs/Outputs......................................................................................................................................... 20
6.2 Registers ................................................................................................................................................... 20
6.3 Position registers ..................................................................................................................................... 20
7. Programming .............................................................................................................................................. 21
7.1 Cycle trajectories ..................................................................................................................................... 21
7.2 Cleaning trajectories ................................................................................................................................ 22
8. Error during process ................................................................................................................................... 23
8.1 Pressure out of tolerance ........................................................................................................................ 23
8.2 Unknown roller hemming ........................................................................................................................ 23
8.3 Incompatible type .................................................................................................................................... 24
8.4 Read parameter failed ............................................................................................................................. 24
8.5 Invalid UTOOL number............................................................................................................................. 24
8.6 Pb reading debug mode input ................................................................................................................. 24
8.7 Missing pressure feedback ...................................................................................................................... 25
8.8 Invalid calibration......................................................................................................................................... 25
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8.9 Wrong direction parameter ..................................................................................................................... 25
8.10 Scale problem ........................................................................................................................................ 25
8.11 Undefined trajectory.............................................................................................................................. 25
8.12 Cleaning needed .................................................................................................................................... 26
9. Information about how to use the UTOOL ................................................................................................. 27
10. CORNER REGION (CR) terminaison type ................................................................................................. 30
11. Information about “J570 - Controlled stop by E-Stop” option.............................................................. 32
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1. Applicative screen
1.1 Main screen
Access to the SABB application's main screen (and to all the secondary screens) is reached by pressing the
MACRO 7 key
Key MACRO 7 (Applicative menu)
After pressing the MACRO 7 key, a screen will appear, press F1 : TYPE and select « ROLLER HEMMING ».
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The main screen allows you to find all the informations relative to the current cycle.
Actual tool : Head currently used, 12 heads are available.
Iteration number : Number of iteration that is currently being done. This number is stored in a Register that
must be updated in production trajectories.
Actual UTOOL: UTOOL used for this iteration. The trajectories use the same working TOOL (TOOL 1), but the
coordinates of this TOOL are updated by the routine RH_OFFS.
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Actual pressure: Pressure currently used in the activated head. The pressure is set by the routine RH_PRESS.
Actual direction : Direction sets for the head actually used. 2 directions are available PUSH or PULL. The
direction is set by the routine RH_PRESS.
Offset enable: Allows the operator to know if the trajectory offset is activated or not. This parameter will be
set to INACTIVATED if the offset of the 6 coordinates equals 0.
Offset in X : Offset in X (mm).
Offset in Y : Offset in Y (mm).
Offset in Z : Offset in Z (mm).
Offset in W : Offset in W (°).
Offset in P : Offset in P (°).
Offset in R : Offset in R (°).
1.2 CALIBRATION screen
Access to the calibration screen is done by pressing F3 : MENU in any SABB applicative screens and choosing
CALIBRATION in the pop up menu.
This screen allows you to perform the calibration for a specified head (12 heads available). The calibration
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allows the system to calculate how many volts are needed for a 1daN pressure.
Tool number: Number of the head to calibrate (12 heads available).
Direction: Direction used for the calibration, PUSH or PULL.
Pressure (daN): Table filed with the measured pressures for 1,2,3,4 and 5volts.
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1.3 MANUAL TEST screen
Access to the test screen is done by pressing F3 : MENU in any SABB applicative screens and choosing ESSAIS
in the pop up menu.
This screen allows you to verify if the calibration is ok or not. In this screen you can set the pressure value
that you want and measure in the output if you have the good pressure. If there Is a difference between
what you ask and what you get  Redo the calibration.
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Direction: Direction used for the calibration, PUSH or PULL.
Pressure (daN): Pressure in daN that you want to set.
1.4 SERVICES screen
Access to the test screen is done by pressing F3 : MENU in any SABB applicative screens and choosing
SERVICE in the pop up menu.
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This screen allows you for each heads (12 heads available) to specify the maximum number of cycle before
an automatic cleaning trajectory, and the name of the cleaning trajectory that will be automatically executed
when the maximum cycle is reached.
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Actual count: The counter is increased each time the TPE routine RH_SERV_TP is used and reseted every
time the TPE routine RH_CLEAN_TP is used. (See routines chapter)
Max parts : This value need to be set to specify how many workpiece must be done before cleaning
trajectory is executed. If the value is set to 0, the function is disabled.
Cleaning trajectory : Name of the trajectory that will be executed when the number of workpiece currently
done reached the max workpiece counter.
1.5 DEBUGGING OFFSET screen
Access to the debugging screen is done by pressing F3 : MENU in any SABB applicative screens and choosing
DEVERMINAGE in the pop up menu.
This screen allows you to specify the offset in X, Y and Z (mm) that will be applied to every TOOL if the debug
mode is activated. The debug mode is activated with an INPUT, the offset is activated when the routine
RH_OFFS is used.
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Offset in X : Offset in X in mm set the value that you want (Value allowed between -500 and 500mm).
Offset in Y : Offset in Y in mm set the value that you want (Value allowed between -500 and 500mm).
Offset in Z : Offset in Z in mm set the value that you want (Value allowed between -500 and 500mm).
Careful, the default value is 10mm for Z
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2. How to do the calibration
 Put the robot in a desired position.

 Put a pressure gauge under the roller hemming head .
 Select the calibration screen.
 Switch the Teach in ON position.
 Select the head you want to calibrate (12 heads available).
 Select the direction (PUSH or PULL) by pressing the button.
 Hold the Deadman and keep the SHIFT key pressed.
 Press the arrow button under ACTION field every arrow is linked to a specified voltage (1,2,3,4,5
volts).
 A pop up ask you if the robot is in good position.
o YES  The pressure is enabled in the roller hemming head.
o NO  Calibration is aborted.
 If YES has been pushed, read the value in the pressure gauge, wait for the end of the movement
(2seconds) and write the value in the PRESSION (daN) field in the correct line.
 Do the same for the 4 voltages left.
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3. How to use the test mode
 Put the robot in a desired position.

 Put a pressure gauge under the roller hemming head .
 Select the test screen.
 Switch the Teach in ON position.
 Select the head you want to calibrate (12 heads available).
 Select the direction (PUSH or PULL) by pressing the button.
 Set the pressure to the desired value in the field « Valeur de pression (daN) ». (Value allowed
between 50 and 400daN max)
 Hold the Deadman and keep the SHIFT key pressed.
 Press the PRESSION button.
 A pop up ask you if the robot is in good position.
o YES  The pressure is enabled in the roller hemming head.
o NO  Test is aborted.
 If YES has been pushed, read the value in the pressure gauge, wait for the end of the movement
(2seconds) and verify that is the pressure you asked for. If the pressure read is wrong, verify the
calibration.
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4. Routines
Routines are Karel programs developed to do some specific tasks. You have to use it in the trajectories.
4.1 RH_OFFS
RH_OFFS(Head number, UTOOL number, Offset X, Offset Y, Offset Z, Offset W, Offset P, Offset R)
This Routine sets offsets used in argument + those used in the DEBUGGING screen (if the debugging mode is
activated) into the PR[99]. The PR[99] needs to be used in trajectories.
This routine also makes a copy of the coordinates of the UTOOL specified in argument into the UTOOL 1.
Arguments :
Head number : Value allowed between 1 and 12, select the head that you want to use.
UTOOL number : Value allowed between 2 and 10. UTOOL number linked to the desired head. Those
UTOOL’s coordinates are copied in the UTOOL 1 during the process.
Offset X,Y,Z : Offset in mm to set.
Offset W,P,R : Offset in ° to set.
Example :
CALL RH_OFFS(2,3,10,0,0,0,0,90)
Set an offset of X :10mm, Y :0mm, Z :0mm, W :0°, P :0°, R :90° to the head number 2 that uses UTOOL 3.
Notes :
 This routine must be used every time in the beginning of each trajectories even there is no « cycle
offsets » to set the values for « debugging offsets ».
 The « debugging offsets » are stored in PR[98], is the debugging mode is deactivated, the
coordinates of the PR[98] equal zero.
 The « cycle offsets » are stored in PR[97].
 The « final offset » is stored in PR[99], PR[99] = PR[97]+PR[98].
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4.2 RH_PRESS
RH_PRESS (Head number, pressure, direction)

This routine allows you to set a pressure to a specified head. Two directions are available, PUSH or PULL.
Arguments :
Pressure : Value allowed between 0 and 400 daN (Or less if the calibration doesn’t allow you to set this
value).
Direction : 0 = PULL, 1 = PUSH
Example :
CALL RH_PRESS(1, 275, 1)
Pressure of 275daN for the head 1 in PUSH mode.
4.3 RH_SERV
RH_SERV(Head number)
This routine increments the workpiece counter and check if a service is needed (Workpiece counter
superior or equal to the max workpiece reference  See the Service screen).
This routine doesn’t need to be used, it is used in the trajectory RH_SERV_TP.TP that you have to insert at
the end of all your cycle trajectories (See the programming chapter).
Arguments :
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4.4 RH_CLEAN
RH_CLEAN(Head number)
This routine resets the workpiece counter.
This routine doesn’t need to be used, it is used in the trajectory RH_CLEAN_TP.TP that you have to insert at
the end of all your service trajectories (See the programming chapter).
Arguments :
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5. Programs
The programs are made in TPE, you get them with the SABB applicative, you must NOT modify them.
5.1 RH_PROC_TP
RH_PROC_TP
This program allows the robot to display a fault message if, during the cycle, the FEEDBACK information
goes OFF when pressuring the head.
This program needs to be used at the end of each cycle trajectories.
In case of fault, 2 answers are available :

 YES  The cycle is PAUSED, the operator can have a look to see what the problem is. After checking,
he can restart the cycle from where it was paused.
 NO  The robot continue its cycle.
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5.2 RH_SERV_TP
RH_SERV_TP (Head number)

This program verifies if an automatic service is needed. In that case, it executes the program specified in the
SERVICE screen. This program is the one calling the routine RH_SERV.
You need to use this at the end of each cycle trajectories.
Arguments :
5.3 RH_CLEAN_TP
RH_CLEAN_TP (Head number)

This program resets the workpiece counter and displays a message to ask the operator to clean the head.
This program must be used in SERVICE trajectories.
When OK is pressed, the cycle is PAUSED, after that the operator can enter in the work cell.
Arguments :
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6. Inputs/Outputs, Registers, Position registers
Some data are used by the SABB applicative, don’t modify them !
6.1 Inputs/Outputs
2 inputs are used :

 DI[802 : RH FEEDBACK] : This input allows you to know if there is a problem with the pressure. A
background task (BG logic program  RH_BG.TP), is checking if when a pressure is set, the DI goes to
OFF for more than 500ms, in that case, at the end of the cycle a fault will be displayed with the
program RH_PROC_TP.TPE.
 DI[5 : API : DEV] : This is an input from the Renault RARN applicative, when it’s on, the debugging
mode is activated.
3 outputs are used :

 DO[58 : DO_FAULT] : The output is used to tell the API that there is a pressure fault. It’s set to ON
when there is a pressure problem (DI[FEEDBACK] at OFF for more than 500ms) and goes back to OFF
when the DI[FEEDBACK] goes back to ON.
 DO[801 : DO_PUSH] : Output that selects the PUSH mode.
 DO[803 : DO_PULL] : Output that selects the PULL mode.
2 analog outputs (In the robot you will find them in the GO menu) are used :
 GO[50 : RH PRESSURE] : Output that sets the pressure.
 GO[51 : RH CHANNEL] : Output used to select the channel in the analog card (Internal Fanuc don’t
touch it).
6.2 Registers
Registers 101 to 113 are for the SABB applicative, Don’t use them !!!
6.3 Position registers
Position registers 97, 98 and 99 are for the SABB applicative, Don’t modify them !!!
The only position register that have to be used in the trajectories is the PR[99] (global offset)  See
programming chapter.
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7. Programming
To use the SABB applicative, you must program your trajectories a certain way. It’s important for 2 kind of
trajectories:
 Cycle trajectories.
 Cleaning trajectories.
7.1 Cycle trajectories
Cycle trajectories must be teached with the UTOOL 1. The coordinates of the UTOOL 1 are updated by the
routine RH_OFFS by copying the coordinates of the head that you want to use, those coordinates are stored
in UTOOL 2 to 10. The cycle trajectories must use some routines to work properly.
Standard example for 1 iteration :
UTOOL_NUM=1  UTOOL 1 for each cycle trajectories

UFRAME_NUM=1  Specify your UFRAME
PAYLOAD[1]  Specify your payload
J PR[2:PT_REB] 100% FINE
! Initialisation for the cycle offset and debugging offset if debugging mode is activated
CALL RH_OFFS(3,2,0,0,(-20),0,0,(-90))
! Pressure initialisation, here 200daN for the head 3 in PUSH mode

CALL RH_PRESS(3,200,1)
! Example of points  YOU MUST USE for each points Tool_Offset,PR[99:Offset RH ]

L P[1] 2000mm/sec FINE Tool_Offset,PR[99:Offset RH]
! Pressure reset, 0daN on head 3 in PUSH mode

CALL RH_PRESS(3,0,1)
! Control if process is ok (drop of DI[FEEDBACK])

CALL RH_PROC_TP
! Control if cleaning cycle is needed
CALL RH_SERV_TP(3)  Cleaning for head 3
J PR[2:PT_REB] 100% FINE
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If you are doing more than one roller hemming iteration, you have to make some loop in your trajectories to
redo the work. This process can be done with different pressures or different offsets by using registers as
parameters in the RH_OFFS and RH_PRESS routines.
Example of indirect parameters:
CALL RH_OFFS(R[120],R[121],0,0,R[122],0,0,R[123)]
In this example:
R[120] : Register for the head number.
R[121] : Register for the UTOOL number.
R[122] : Register for the Z offset (in mm).
R[123] : Register for the R offset (in °).
CALL RH_PRESS(R[120], R[124],1)
In this example:
R[120] : Register for the head number.
R[124] : Register for the pressure in daN.
7.2 Cleaning trajectories
Cleaning trajectories are automatically executed when the workpiece counter reached the max workpiece
allowed. Those trajectories must call the RH_CLEAN_TP program to reset the workpiece counter.
Example :
UFRAME_NUM=1  Specify your UFRAME

UTOOL_NUM=1  UTOOL 1 for each cleaning trajectories
PAYLOAD[1]  Specify your payload
J P[1] 100% FINE  Cleaning trajectory

! Reset the workpiece counter for the head 3

CALL RH_CLEAN_TP(3)
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8. Error during process
Careful, all the error that appears during the process abort the cycle !
8.1 Pressure out of tolerance
In the « test screen » or when the routine Rh_PRESS is used, an invalid pressure has been set. If the fault
appears in the test screen, the pressure is automatically set to the highest value available.
 If the routine RH_PRESS is used, set a good pressure value. The pressure can be higher than 400daN
in the best of case (depends of the calibration).
8.2 Unknown roller hemming
Can appear when using :

- RH_CLEAN (Called by program RH_CLEAN_TP)
- RH_OFFS
- RH_PRESS
- RH_SERV (Called by program RH_SERV_TP)
The parameter used for the head is wrong. Value allowed between 1 and 12.
 Modify the parameter for the head value.
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8.3 Incompatible type

- RH_OFFS
- RH_PRESS
One or more of the parameters that are used in the routine are incorrect (Real instead of integer, Integer
instead of real, string instead of real, …).
 Verify the parameters.
8.4 Read parameter failed

- RH_OFFS
- RH_PRESS
One or more of the parameters that are normally used in the routine are missing.
 Specify all the needed parameters.
8.5 Invalid UTOOL number

- RH_OFFS
The UTOOL number use dis invalid. Value allowed, between 2 and the maximum of UTOOL available (10 is
the default value).
 Set a good value for the UTOOL.
8.6 Pb reading debug mode input

- RH_OFFS
Problem occurs when reading the state of the input used to set the debugging mode.
 Check if the RARN applicative is fully functional.
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8.7 Missing pressure feedback

- RH_PRESS
This fault appears when a pressure is set with the routine RH_PRESS but the FEEDBACK input information is
at OFF.
 Verify the FEEDBACK input.
8.8 Invalid calibration

- RH_PRESS
Appears when using the routine RH_PRESS without making the calibration.
 Calibrate the system. (See chapter 2)
8.9 Wrong direction parameter

- RH_PRESS
The parameter used for the direction is invalid. 2 values are allowed :
- 0 = PULL mode.
- 1 = PUSH mode.
 Set an allowed value.
8.10 Scale problem

- RH_PRESS
The pressure sets is allowed (between 0 and 400daN) but can be reached due to calibration (A voltage
higher than 10v must be used to reach this pressure and it’s impossible for the Fanuc analog output card).
 Verifiy if the calibration is ok, if the calibration is ok, lower the pressure. (Example, for a “linear”
calibration, the higher value equal 2 times the pressure value sets for 5v in calibration screen).
8.11 Undefined trajectory

An automatic cleaning trajectory is called but it’s missing in the robot.
 In the configuration menu (See chapter 1.4), set a proper name for the cleaning trajectory and create the
trajectory in the robot.
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8.12 Cleaning needed

The number of workpieces before cleaning counter reached the maximum allowed but no trajectory name
has been set in the configuration menu.
 In the configuration menu (See chapter 1.4), set a proper name for the cleaning trajectory and create the
trajectory in the robot.
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9. Information about how to use the UTOOL
All the process trajectories must used the UTOOL 1. The UTOOL 1 is a temporary UTOOL that is updated with
the good coordinates, every time the routine RH_OFFS is used. Every roller hemming head is linked to a
specify UTOOL.
Teaching UTOOL is done this way :

- Tool 1  Do not teach, do not modify, it is updated by RH_OFFS routine.
- Tool 2  UTOOL for head 1, it must be teached.
- Tool 3  UTOOL for head 2, it must be teached
- Tool 4  UTOOL for head 3, it must be teached
- ….
Careful: When teaching UTOOL, direction is a crucial point.
Example with inverted UTOOLS :
Using head 1 (TOOL 2) Y TOOL 3
X
Head 2
Head 1
X
Y TOOL 2
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Using head 2 (TOOL 3), 180° rotation
Y TOOL 2
X
Head 1
Head 2
X
Y TOOL 3
Example with UTOOLS in the same direction :
Using head 1 (TOOL 2)
X TOOL 3
Head 2
Y
Head 1
X
Y TOOL 2
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Using head 2 (TOOL 3), head offset
X TOOL 3
Head 2
Y
Head 1
X
Y TOOL 2
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10. CORNER REGION (CR) terminaison type
L P[2] 100 mm/sec Cry
CRy is an optional termination type that can be used to adjust the corner rounding for Cartesian
motions. When you use the CR termination type, you must specify the corner region value, y, (in
millimeters).
Corner Region value is the distance from the starting of a corner path to the taught position, as
shown in the following figure. When CRy is specified, TCP path will maintain the corner path within
the specified region, meaning that the actual distance from the starting/ending of a corner path to
the taught position is less than or equal to the specified corner region value (y).
When you set corner region, use the following guidelines:

- Specify the corner region in millimeters
- Corner region value can range in value from 0 mm to 1000 mm
- The smaller the corner region value, the closer the robot will get to the taught position, and
the less the corner rounding
- With a larger corner region value specified, the robot will not get as close to the position and
the more corner rounding
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CRy versus segment distance

If the specified corner region value, y, is greater than half the segment distance, then the actual
value used is limited to half segment distance as shown below
Teaching Techniques
You must be careful about the half distance rule stated above. Keep in mind that because of the
half distance rule, with large specified corner region value, corner path may still be close to the
taught position when the segment distance is short. Use the following guidelines when you teach a
path:
- Minimize the number of taught positions
- Reteach positions using the CR termination type to fit the path instead of adding positions
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11. Information about “J570 - Controlled stop by E-Stop” option
In some case (when you use a turn table for example) you have to use “J570 - Controlled stop by E-Stop”
option. When the option is specified, the stop type becomes Controlled stop but only in AUTO mode.
Controlled stop is different from Power-Off stop as follows:

- In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems
where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized.
- The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis.
This function is activated only for the following alarms:
Défaut Condition d'apparition

SRVO-001 Operator panel E-stop Operator panel emergency stop is pressed.
SRVO-002 Teach pendant E-stop Teach pendant emergency stop is pressed.
External emergency stop input (EES1-EES11, EES2-EES21) is
SRVO-007 External emergency stops open.
SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF.
SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.
In all the other cases (Switching Teach pendant to ON, Switching AUTO key to T1/T2) the stop type will be
Power-OFF stop which is the normal operation for the system. So in all the other cases you have to pause
the robot first (HOLD button in the Teach pendant, STOP input sent by the PLC) or to make a « clean stop »
(Home position request).

Integration Guide For The Fanuc RARN SABB Application v1.0

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Integration Guide For The Fanuc RARN SABB Application v1.0

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Integration Guide For The Fanuc RARN SABB Application v1.0

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FANUC France Tél.

Key MACRO 7 (Applicative menu)

Actual tool : Head currently used, 12 heads are available.

Offset in X : Offset in X (mm).

Offset in Y : Offset in Y (mm).

Offset in Z : Offset in Z (mm).

Offset in W : Offset in W (°).

Offset in P : Offset in P (°).

Offset in R : Offset in R (°).

1.2 CALIBRATION screen

Tool number: Number of the head to calibrate (12 heads available).

Direction: Direction used for the calibration, PUSH or PULL.

1.3 MANUAL TEST screen

Tool number: Number of the head to calibrate (12 heads available).

Direction: Direction used for the calibration, PUSH or PULL.

Pressure (daN): Pressure in daN that you want to set.

1.4 SERVICES screen

Tool number: Number of the head to calibrate (12 heads available).

1.5 DEBUGGING OFFSET screen

2. How to do the calibration

 Put the robot in a desired position.

3. How to use the test mode

 Put the robot in a desired position.

Offset X,Y,Z : Offset in mm to set.

Offset W,P,R : Offset in ° to set.

RH_PRESS (Head number, pressure, direction)

Direction : 0 = PULL, 1 = PUSH

In case of fault, 2 answers are available :

RH_SERV_TP (Head number)

RH_CLEAN_TP (Head number)

2 inputs are used :

3 outputs are used :

6.3 Position registers

7.1 Cycle trajectories

Standard example for 1 iteration :

UTOOL_NUM=1  UTOOL 1 for each cycle trajectories

J PR[2:PT_REB] 100% FINE

! Pressure initialisation, here 200daN for the head 3 in PUSH mode

! Example of points  YOU MUST USE for each points Tool_Offset,PR[99:Offset RH ]

! Pressure reset, 0daN on head 3 in PUSH mode

! Control if process is ok (drop of DI[FEEDBACK])

J PR[2:PT_REB] 100% FINE

Example of indirect parameters:

CALL RH_PRESS(R[120], R[124],1)

7.2 Cleaning trajectories

UFRAME_NUM=1  Specify your UFRAME

J P[1] 100% FINE  Cleaning trajectory

! Reset the workpiece counter for the head 3

8. Error during process

8.1 Pressure out of tolerance

8.2 Unknown roller hemming

Can appear when using :

Can appear when using :

8.4 Read parameter failed

Can appear when using :

8.5 Invalid UTOOL number

Can appear when using :

8.6 Pb reading debug mode input

Can appear when using :