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This procedure will help you set up a job with your Haas Robot.

Follow the First Power Up section in the Haas Robot Installation Guide to connect the robot to your Haas machine.

 Note: If the machine is Cycle Powered before saving a job, the template info may be lost.

Before setting up a robot job you will need to create a user frame. The user frame will be off the parts table. This will set our X, Y, and Z axes.

There are two coordinate types to jog the robot in. These are Cartesian and Joint. 

The Cartesian coordinate system consists of:

• X, Y, and Z are linear axes.
• W rotates about the X axis.
• P rotates about the Y axis.
• R rotates about the Z axis.

The Joint coordinate system consists of:

• J1, J2, J3, J4, J5, and J6.

Robot Joint Travel Limits

J1 (+/-170°)

J2 (+/-122.5°)

J3 (+/-215°)

J4 (+/-190°)

J5 (+/-125°)

J6 (+/-360°)

The Three Point Method is used to set our User Frame. Navigate to Current Commands > Devices > Robot > Frames and to the User Frames window. Press [F2] to switch boxes.

Press [INSERT] for the Three Point Method. Then enter a name for the User Frame and press [F2] to record.

The first point you will record is the orient point. This will be set with gripper 1’s fingers pointing down and on the table. Jog the robot to this location. Check to make sure all 4 grippers are flat on the table with a piece of paper like touching off a tool on a part. Once our orient point[1] is set, press [F2] to record.

The next point is the X Direction point. Record the Z position on the RJH when in Cartesian Position. Jog the robot up in the Z direction so the gripper fingers clear the table when jogging in the X direction. Jog the robot in the X direction and back to the recorded Z position. The fingers should be touching the table, use the piece of paper to set the grippers back on the table. Record the X direction point[2] by pressing [F2].

Jog the robot in the Y direction. Because the robot is mounted at a 30 degree angle, the Y-direction will travel up away from the table. Jog down in the Z direction back to the table and use the piece of paper to touch off the gripper fingers. Record the Y direction point[3] by pressing [F2].

The Direct Entry Method can also be used to set our User Frame. Navigate to Current Commands > Devices > Robot > Frames and to the User Frames window. Press [F2] to switch boxes.

For Robot Package 1 VF/VM & ST Machines Only

Press [ENTER] for the Direct Entry Method. To set the User Frame off of the robot stand. Enter a name for the User Frame and add the following values:

• X = 0.0
• Y = 0.0
• Z = 0.0
• W = 0.0
• P = -30.0
• R = 180.0

This will rotate the robot about Y 30 degrees and Z 180 degrees. The robot will jog with the Z direction perpendicular to the table. Press [ENTER] to record.

Press [Insert] to create the User Frame. Navigate to the Jogging tab and select the User Frame that was created to make it active.

Each Haas Robot is provided with FANUC's DCS System. This allows the user to define speed and positional limits to the robot. If the robot goes outside of these limits, DCS will stop the robot and remove power to the motors.

This procedure will show you how to set up a Fanuc Dual Check Safety (DCS) zone.

Operation

• Max Robot Speed – This setting specifies the maximum robot  speed when the machine is in Run Mode. Enter the speed in the correct units (in/sec or mm/sec) to run the job. This setting can be adjusted up or down if the program requires.
  
  Note: The maximum Robot speed in Run Mode is 157 in/sec (4000 mm/sec). 
  The maximum Robot speed in Setup Mode is 7.9 in/sec (200 mm/sec).
  
  
• Gripper Net Mass – Enter the net mass of the gripper. See the Robot Layout Drawing for gripper mass.
• Number of Grippers - Enter the number of grippers.

To disable the robot to run the machine in stand-alone mode. Press [SETTING]. Change the following Settings:

• 372 Parts Loader Type to 0: None
• 376 Light Curtain Enabled to Off

In order for the dual grippers to reach the vise, the B axis may need to be tilted away from the robot. 

This is the case for all UMCs with HRP-2. 

Once a loading position is determined, the loading position can be saved by going to Current Commands -> Devices -> Automatic Part Loader -> Load part [2] -> Internal Axes Location for Load [1].  Press F2 to set the current position of the machine as the loading position. 

More information about setting up HRP templates can be found at HRP - Operations. 

If the load and unload locations need to be different, custom templates will need to be used. HRP - Operations - 9.3 - Custom template. 

Sequence Type – Enter 0 for Simple Template or 1 for Custom Sequence. See the Custom Sequence Section for more information.

Raw Stock Pickup Method – Enter 0 for Table Grid or 1 for Single Point.

Finished Part Drop Off Method – Enter 0 for for Single Table, 1 for Dual Table, or 2 for Single Point.

Number of Stacked Parts – Enter the number of stacked parts per pocket. Maximum 3 parts.

Note: If using the stacked part feature of two or three parts and the Raw Stock Pickup Method and Finished Part Drop Off Method are both single table. The first part location must be empty.

Number of Rows – Enter the number of rows you want to use on the table.

Numbers of Columns – Enter the number of columns you want to use on the table.

Note: For the next setup operations the following commands are available:

• Press [TURRET FWD] OR [TURRET REV] to index the tool changer. This will be used when setting the Safe Axes Location for Load position

• Press [F2] to set the reference position. This records the current robot position.

• Press [F3] to clamp/unclamp the gripper. In the Load Part tab gripper 1 is clamped or unclamped. In the Unload Part tab gripper 2 is actuated.

• Press [F4] to clamp/unclamp the main spindle chuck.

Robot Speed – Enter the speed for the robot motions at the parts table. Start at a slow speed during setup and after verifying that the job runs correctly, update the speed to the desired cycle time.

• Slow 1 in/s
• Medium 3 in/s
• Fast 6 in/s 

Initial Pickup Location – Jog gripper 1 to the first part location on the parts table. Clamp the part by pressing [F3] and then press [F2] to record the reference position.

Tips & Tricks: Pick up the part and realign the part to the first part location on the template and record that position. This will better align the gripper to the part and table.

Move to Above Table – Jog the robot in the Z direction to clear all the parts on the table and press [F2] to record the reference position. This location is also the Recovery Position.

Ready Location – Create a motion file that moves the robot from the Above Table Location to the Ready Location. It should be outside the door, with gripper 1 rotated to place the part in the chuck.

Press [ENTER] to create a motion file and press [F1] for Setup Options.

• Press [1] to set coordinates to Joint.
• Press [2] to set the speed.
• Press [3] to set Tool Frame to 1 World Frame.
• Press [4] to set User Frame to the User Frame created from the Three Point Method.

Jog the robot from the Above Table Location to outside the door while rotating gripper 1. Record positions along the path to create a smooth motion.

Tips & Tricks: Set the first point for this motion file to be away from the Above Table Location in the X & Y direction.

Safe Axes Location for Load – Jog the internal axes to ensure the Tool Changer, tools, and B-Axis are clear when loading parts. Press [F2] to record the reference position.

C Axis Orient Position – This field is used to set the chuck orientation when loading a part. Follow the on screen instructions to set the values.

Note: Lathes without a C-Axis or spindle home switch cannot guarantee repeatable spindle orientations, because of this if there is an application that requires a specific spindle orientation then the orientation must be checked and verified when a job is set up and before running any job. 

Chuck Load Location – Create a motion file that moves the robot from the Ready Location to the Chuck Load Location.

Tips & Tricks: The first location recorded in the motion file should be the last location in the Ready Location motion file. Outside the door, with gripper 1 rotated to place the part in the chuck.

Finish Workholding – Select the workholding mechanism to clamp the finished part.

Chuck Pick Up Location – Create a motion file that moves the robot from the Ready Location to the Chuck Pick Up Location. With gripper 2 unclamped, jog and rotate gripper 2 to spindle centerline and locate and clamp the part. When clamping gripper 2, check for movement of the robot and adjust to center the gripper to the part.

Gripper Swap Location – Create a motion file that moves the robot from the Chuck Pick Up Location to the Gripper Swap Location. Jog the robot along spindle centerline away from the chuck and rotate the gripper so gripper 1 is aligned to spindle centerline.

Load After Swap – Create a motion file that moves the robot from Gripper Swap Location to the Chuck Load Location. With the workholding unclamped, jog gripper 1 along spindle centerline towards the chuck. The part should be centered in the jaws and against the back of the jaws. Clamp the chuck and check for movement of the part. Adjust to center the part to the workholding.

The Run Job tab allows you to load/run and save a job. It also shows the current Robot mode status and current job running. The file name will be red if the job is not saved and black if saved.

Press [F3] to save the job, type in the desired job name and select the file location. To save the job to the same file location after editing press [INSERT] two times.

Press [F4] to load a job.

Press [F2] to create a new job.

Press [INSERT] to turn APL Mode On/Off.

Press [UNDO] to move robot to Safe Position. This location is the Move to Above Table location recorded on the Load Part tab. If this position is not recorded, this feature is not available. 

Warning: Do not use this feature if the robot is not in a safe position to move from its current position to the Above Table location.

The first part of the machining program must be an operation to seat the SLUG properly on the Jaws shoulder or stop. The Haas supplied spring plunger can be used or any custom made tool. The Plunger like any tool must have it’s own tool offset and station on the turret.

• Approach part in rapid motion and stop approximately 0.25” (6 mm) from the part.
• Feed in and push plunger against the part until spring has compressed ½” (12 mm).
• Open and Close the chuck using M11 and M10 for part to seat.
• Retract away from the part in Rapid motion and proceed with machining process

After setting up the Job press [INSERT] to turn on APL Mode.

Note: When the machine is in APL Mode the control will load the next part when the machine executes an M299 code. When not running in APL mode the M299 takes the place of an M30 or M99 at the end of a program.

More information on programming can be found in the Operator's Manual.

Press CYCLE START to start your program.

The APL scheduler tab allows the user to schedule Robot Jobs.

Note: Turn Setting 131 to OFF to run scheduled jobs.

Job Number: Specifies the job number. Press [ENTER] to create a Program Comment for the Job.

Order: Specifies the order of the jobs. This can be edited to change the order of the scheduled jobs. Press [ENTER] to set the job order.

Status: Specifies if the job is Unscheduled, Scheduled, or Completed. Press [ENTER] to show the Job Status options.

Parts Count: Specifies how many parts the current scheduled job has run. Press [ENTER] to set the part count.

Job Name: This allows the user to select the Robot Job XML. Press [ENTER] to select the Robot Job.

Program Path: Displays the program path that is selected for the job. The program is selected in the Run Job tab.

Prog Comment: Displays the Program Comment entered by the user.

[ENTER] Varies on the current column. See previous section for column info.

[ALTER] Load Job. Loads the highlighted job into the Run Job tab.

[INSERT] Scheduler Mode On/Off. This turns the Scheduler Mode On or Off. This must be set to On to run a Job Schedule. Follows the same rules as APL Mode.

[F2] Schedule. Schedules the highlighted job.

[F3] Add Row. Adds a new Job Number to the APL scheduler.

[DELETE] Delete Row. Deletes the highlighted job. Scheduled jobs cannot be deleted.

Note: The robot will move to the Ready Location of the current job before moving to the next job in the APL Scheduler. Make sure the Ready Location for all jobs will be a safe location and there are no obstructions.

Sequence Type – Enter 0 for Simple Template or 1 for Custom Sequence.

Number of Stacked Parts – Enter the number of stacked parts per pocket. Maximum 3 parts.

Note: If using the stacked part feature of two or three parts and the Raw Stock Pickup Method and Finished Part Drop Off Method are both single table. The first part location must be empty.

Number of Rows – Enter the number of rows you want to use on the table.

Numbers of Columns – Enter the number of columns you want to use on the table.

Distance Between Rows – Enter the incremental distance between the rows.

Distance Between Columns – Enter the incremental distance between the columns.

The Custom tab allows the user to create a set of user defined sequences. Each row is a sequence with an Alias Code, Description of the sequence, and File name.

The sequence is called in the program with M300 Pn. The P code number corresponds to the Alias Code in the current Custom Sequence.

File: Displays the Custom Sequence path that is currently loaded. If the File path is red, it is edited and not saved. The file type is .SQC.

[INSERT] Inserts a row above the higlighted sequence.

[DELETE] Deletes the highlighted sequence.

[ALTER] Renames a Custom Sequence.

Press [F2] to open the Custom Recorder window, this allows the user to create a custom motion file.

[INSERT] Insert a new row.

[DELETE] Delete the current highlighted row.

[ENTER] Record Options.

• Press [1] to Record Position.
• Press [2] to set speed.
• Press [3] to set the Gripper State.
• Press [4] to set Workholding State
• Press [5] to command the Air Blast.
• Press [6] to command the Auto Door state.
• Press [7] to set the Main/Sub Spindle Orient.
• Press [8] to set a Machine Dwell or Robot Dwell.
• Press [9] to set the state of the robot Pickup or Dropoff. This is used to increment the part counter.
• Press [10] to Increment Part Indices.

The Run Job tab allows you to load/run and save a job. It also shows the current Robot mode status and current job running. The file name will be red if the job is not saved and black if saved.

Press [F3] to save the job, type in the desired job name and select the file location. To save the job to the same file location after editing press [INSERT] two times.

Press [F4] to load a job.

Press [F2] to create a new job.

Press [INSERT] to turn APL Mode On/Off.

Press [UNDO] to move robot to Safe Position. This location is the Move to Above Table location recorded on the Load Part tab. If this position is not recorded, this feature is not available. 

Warning: Do not use this feature if the robot is not in a safe position to move from its current position to the Above Table location.

The first part of the machining program must be an operation to seat the SLUG properly on the Jaws shoulder or stop. The Haas supplied spring plunger can be used or any custom made tool. The Plunger like any tool must have it’s own tool offset and station on the turret.

• Approach part in rapid motion and stop approximately 0.25” (6 mm) from the part.
• Feed in and push plunger against the part until spring has compressed ½” (12 mm).
• Open and Close the chuck using M11 and M10 for part to seat.
• Retract away from the part in Rapid motion and proceed with machining process

After setting up the Job press [INSERT] to turn on APL Mode.

Note: When the machine is in APL Mode the control will load the next part when the machine executes an M299 code. When not running in APL mode the M299 takes the place of an M30 or M99 at the end of a program.

More information on programming can be found in the Operator's Manual.

Press CYCLE START to start your program.

%
O61121 (CUSTOM PROGRAM);
(#62715 = Current Part);
(#62719 = Max Part Number);
(P1 = FIRST PART PICKUP);
(P2 = MOVE TO READY);
(P3 = LOAD PART INTO CHUCK);
(P4 = UNLOAD THE FINISHED PART);
(P5 = DROPOFF PART);
;
M97 P10 (CALL ROBOT LOAD PROGRAM);
M98 P111 (PART PROGRAM);
M97 P20 (CALL ROBOT UNLOAD PROGRAM);
;
M99; 
;
N10 (ROBOT LOAD PROGRAM);
M300 P1 (FIRST PART PICKUP);
M300 P2 (MOVE TO READY);
;
T4 G00 Y-1. Z-2. (MOVES INTERNAL AXES TO SAFE LOCATIONS);
;
M80 (DOOR OPEN);
;
G04 P5. (DOOR OPEN);
;
M300 P3 (LOAD PART INTO CHUCK);
M300 P3 R0 (BACK TO READY);
;
M81 (DOOR CLOSE);
;
G04 P3. (DOOR CLOSE);
;
M99;
;
N20 (ROBOT UNLOAD PROGRAM);
T4 G00 Y-1. Z-2. (MOVES INTERNAL AXES TO SAFE LOCATIONS);
;
M80 (DOOR OPEN);
;
G04 P2. (DOOR OPEN);
;
M300 P4 (UNLOAD THE FINISHED PART);
;
M300 P4 R0 (BACK TO READY);
;
N200;
;
M81 (DOOR CLOSE);
;
G04 P2. (DOOR CLOSE);
;
N210; 
M300 P2 R0 (MOVE TO DROPOFF TABLE);
M300 P5 (DROPOFF PART);
;
G04 P5.; 
;
N215;
G103 P1 (LIMIT LOOKAHEAD FOR MACRO ASSIGNMENTS); 
IF [ #62715 GT #62719 ] GOTO50;
(FETCH AND TAKE NEXT PART TO READY);
G103;
M99;
;
N50;
M299;
;
%

This is an example of Custom Sequence of a robot with a single gripper.

M300 Pn R0 Plays the Sequence in reverse.

M300 Pn Q0 Plays the sequence in the background to the program.

Note: M300 Pn R0 ignores all non-robot related commands when the motion file is ran in reverse. Example of some commands ignored: Machine Dwells, Auto Door commands, Workholding commands, and Spindle Orients.

The APL scheduler tab allows the user to schedule Robot Jobs.

Note: Turn Setting 131 to OFF to run scheduled jobs.

Job Number: Specifies the job number. Press [ENTER] to create a Program Comment for the Job.

Order: Specifies the order of the jobs. This can be edited to change the order of the scheduled jobs. Press [ENTER] to set the job order.

Status: Specifies if the job is Unscheduled, Scheduled, or Completed. Press [ENTER] to show the Job Status options.

Parts Count: Specifies how many parts the current scheduled job has run. Press [ENTER] to set the part count.

Job Name: This allows the user to select the Robot Job XML. Press [ENTER] to select the Robot Job.

Program Path: Displays the program path that is selected for the job. The program is selected in the Run Job tab.

Prog Comment: Displays the Program Comment entered by the user.

[ENTER] Varies on the current column. See previous section for column info.

[ALTER] Load Job. Loads the highlighted job into the Run Job tab.

[INSERT] Scheduler Mode On/Off. This turns the Scheduler Mode On or Off. This must be set to On to run a Job Schedule. Follows the same rules as APL Mode.

[F2] Schedule. Schedules the highlighted job.

[F3] Add Row. Adds a new Job Number to the APL scheduler.

[DELETE] Delete Row. Deletes the highlighted job. Scheduled jobs cannot be deleted.

If the Automatic Part Loader cycles get interrupted you must enter [RECOVER] mode to correct or complete the cycle.

Press the [RECOVER] , the recovery page will display the Workholding/Gripper status and the Suggested Next Action(s).

Automatic Part Loader Recovery Display:

1. Robot and Machine Functions 
2. Workholding and Gripper Status 
3. Suggested Next Action(s) 

[F2] Clamp Raw Gripper. This will clamp the raw gripper.

[F3] Clamp Finish Gripper. This will clamp the finish gripper.

[F4] Clamp/Unclamp Workholding. This will clamp/unclamp the workholding.

[ALTER] Open/Close Auto Door. This will open or close the auto door.

[ORIGIN] Automatic Recovery. This will attempt to recover the APL automatically to its Above Table Location. A safe position needs to be set up in the Robot Template.

Warning: Do not use this feature if the robot is not in a safe position to move from its current position to the Above Table Location.

[Q] Exit Recovery. This will exit the APL recovery display.