Daihen OTC FD19 User manual

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Introduction of FD19 controller
NE
W

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Growing global automation needs
Background of Developments
Social issues
•Shortage labor
•Shortage skilled workers
•Wage growth
At Middle and
Major customers
of JPN, US, EU, CN
JPN SME’s and Emerging
countries and JPN small
and medium customers
①Highly Automated
request by robot system
②Robotization request to
break away from manual
work

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① Highly automated requests by robot system
Catching up Automation Needs
Expectations
１）Expectations of the full turnkey system
２）Demand from labor saving to unmanning
Changing from single robot to robot system
Become a robotics manufacturer that is easy to cooperate with SIer
Content to be strengthened
・Standardization of the latest safety functions
・ Standardization of handling functions
・ Easy-to-cooperate with other companies' units
・ Various Options can be added by SIer.
・ Improvement of basic robot performance (function)

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① Robotization request to break away from manual
Catching up Automation Needs
Issue
The market is expanding, but it has not been able to deliver products that meet its needs.
[e.g.] Major customers in Indonesia, India and Thailand have not expanded from Japanese-owned
motorcycle and car manufacture for 10 years. Japanese SMEs have decided that securing
human resources overseas if better than introducing robots.
Content to be strengthened
1) Inconsistent cost-effectiveness
2) Uneasy to operate, difficult to use
3) Insufficient maintenance and
support system
etc.
Efforts to lower the hurdles of
introduction
• Easy operation
• Manual less and training less
• Support operation and
maintenance any time

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Solution with FD19 controller
Advanced automation Breaking from manual work
Meeting the growing automation needs by FD19
FD19
controller
with solution
For smartphones
I can use it.
It is expensive to improve
safety
•Standardization of the latest safety
functions
•Standardization of handling functions
•Easy-to-cooperate with other
companies' units
•Various OPs can be added by SIer.
•Improvement of basic robot
performance
Efforts to lower the hurdles of
introduction
•Easy operation
•Realization of instruction manual
less and training less
•Support operations and maintenance
any time

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Enhance the system integration ability, provide a robot controller
capable of meeting various field automation requirements.
Aims of the New Robotic Controller
•Advanced automated
production system aimed
at unmanned operation
•Robotization for braking
out from manual work
•Advancement of system needs in
Japan, Europe, the United States and
China
•Robots that SIer can easily upgrade
•Promote robotization in
Emerging Countries
•Easy-to-install and
easy-to-use robots (No
Instruction Manual, No
Training)
Support
to both󳆫

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Features of the new controller FD19
System Integration
Easy to use for first time
persons
• High-scalability
• Standardization of the latest safety functions
• Extensive cooperation with external devices
and systems
• Improvement of I/O synchronization
performance
• New easy-to-use TP
• Tablet-like operability
• Support by Remote Maintenance
New controller
FD19

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Features of the New Control Unit
System Integration

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■Additional axis configuration with superior scalability
・ Independent two-axis controller*1: Contributing to size and cost reduction
・ Up to 7 kW motor × 2 axes can be controlled by an independent 2-axes controller.
・ Easy installation of additional axis module installation man-hours 60% reduction
・ Five controllers can be connected.
Additional two-axis module
Independent two-axis
controller
Robot controller (up to 8 axes)
Width: 440mm,
25% reduction from FD11
Good extensibility and compact controller
•Compact implementation of required specifications
Two axes
Two axes
Width: 580 mm
6 axes
※1 Planned for Jan. 2020

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High-scalability
CPU rack
PCI 3 slots
CPU Board
Relay unit #1
Field bus
CPU rack
PCIe 2 slots
Spare
Relay unit #2
Ethernet Laser
sensor
QT
■ Increased scalability
•Connecting the
optional equipment to
enable a variety of
combinations.
Combination is
possible by serially
connecting boards.
•Enhancing automation levels with free optional equipment
combinations
Arc IF Welding
power
supply
CAN
•There are combinations
that cannot be constructed
due to hardware
limitations.
■ Limited number of combinations
Laser
sensor
QT
IO board #1 Relay unit #1
IO board #2
Combinations are
not possible due to
restrictions.
CPU Board
SQ Arc IF CAN
Jig
Control
panel
Upper jig
Control
panel
Ethernet
Welding
power
supply
Communications line
Device net
Device net
Laser sensor IF
Field bus

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Advanced safety functions
■Standardized safety requirements*1 from major
automotive customer
■Space-saving facilities can be constructed with
RMU functions.
Position Monitoring
board
In the task program
Working range
● Systems using virtual safety fence capabilities
•Advanced Safety Functions as Standard Equipment
■The RMU function can be easily added with a
position monitoring board.
*1 Industry's highest level of safety function (Emergency stop
functions of Cat. 4, PLe, and SIL3) are certified by third
parties.

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Convenient software PLC
Built-in software PLC can be program creation and edited on PCs.
PC
Ethernet
•PLC program can be created on a PC
•Online debugging is also possible.
•Computer editing software provided as standard
•As five languages (SFC/FBD/LD/ST/IL)
•Support for FC (flow chart)
•Software PLC's PC editing software ISaGRAF *1 Workbench is provided as a
standard*2.
•Strongly Supported Developing PLC program
*1 ISaGRAF is a registered trademark of Rockwell Automation.
*2 It is necessary to issue a license.

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Smooth information linkage with host systems
The robots required by our customers' production control systems can
be easily processed. Supports advanced automation such as Industry
4.0.
Customers' production facilities
(OPC-UA response
Software PLC built-in) * The internal information of the robot to be output is selected
by TP.
Production control
systems ■ Robot operation information
• Robotic data (angles, speeds, motor currents, temperature, etc.)
• Controller data (operating modes, input/output signals, variables, etc.)*1
■ Application data
•Construction information (construction time, work piece information,
abnormality information, etc.)
•Measured values (welding current, voltages, wire feed load, etc.)
Example of internal robot information
Factory network
Robot's internal
information
*1 Planned for Oct. 2019.

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Smooth cooperation with CAD/CAM
It is no longer necessary to divide the data generated by the
CAD/CAM.
Recordable by one program
(No need for program division)
■ In FD11...
・
・
・
Need to split programs and call (CALLP)
•For memory capacity
per task program
Extend by 256 times
•User data
Total memory
capacity increased 40
times (10GB)
① Capturing CAD Drawings (FD-ST)
② Automatically Generate task program ■ In FD19

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Improvement of I/O synchronization performance
■Six-fold improvement in the accuracy of output signal position
reproduction. High-precision machining is possible.
For example
Variation in the position of condition change during laser welding (high speed operation) is
approximately 1/6.
High-precision robot
Laser
Start position
Laser
Ending position
Variations are reduced
to approximately 1/6.
Laser
Oscillator
Signal
controlling
4.2mm
0.7mm
Variation (Max. error)
Moving direction
(Speed 10 m/min)
Condition change
(Linear locus accuracy ±0.15 mm or
less)
(with PLC)

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Increased freedom in multiple robots
Extending the number of registrable
logical system configurations
(units) from 9 to 32
At the same time, 9 logical
system*1 configurations (units) can
be start.
The robot can be operated in the desired combination.
4 robots cooperative 1 unit
3 robots cooperative 4 units
2 robots cooperative 6 units
1 robot multitask 4 units
Management unit 1 unit
Total of 16 units
For a four-robot system...
e.g. Combined robots (two robots)
*1 Number of units that can be started simultaneously when nine or more types of
units are registered

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Functions suitable for laser machining
Laser-oscillator manufacturer exclusive use interface
•Equipped with standard I/F from major laser oscillator
manufacturers
e.g. IPG Photonics
•Setup is completed only by selecting the manufacturer.
⇒ Large reduction in startup man-hours
•The interface can be easily extended by adding a definition file.
Examples of I/F Functions with Laser Oscillator (IPG Photoincs)

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Functions suitable for laser machining
Laser-machining exclusive use command
・ Laser-machining exclusive use command standardized
・ Optimal control of laser machining timing
Ex. Laser ON/OFF, laser power control, and Gas on/off
・ Optimal robot operation for laser machining
Laser machining end command
Laser machining start command
Examples of teachings of laser-machining exclusive use instructions

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Functions suitable for laser machining
Automatic teaching of cutting programming
•The basic cutting pattern program is automatically generated by one touch.
•Automatic programming with center position teaching and radius setting
for arc
•Automatic programming, including piercing
Example of shape cutting teaching
Rectangular cut with RArc cutting
Piercing position
Machining pass

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Visual sensor (2D/3D)
2D visual sensor
3D visual sensor
Bulk picking Picking/placing
Correction of misalignment of grip, etc.
•For 2D sensor → planar geometry recognition applications
•For bin picking of the 3D sensor and bulk components
•Easy to connect to the FD19!
Automating the work carried in from people