Tracked Trolley Robot

Ground-Rail Welding Workstation

Operation Manual

Table of Contents

• I. Preparation Before Operation ...... 3

• II. Tracked Trolley Operating Procedures ...... 6

• III. Software Operating Procedures ...... 8

• IV. Common Problems and Solutions ...... 13

• V. Supplementary Notes ...... 15

I. Preparation Before Operation

Step 1: Power Supply Inspection

Confirm that the main power supply is connected, the voltage is stable, and there is no looseness or short circuit. The figure below shows the main power socket.

Caption: Main power supply and connection interface

Image annotation translations:

• Welding gas

• Compressed air port

• Main power quick connector

• Main power socket

Step 2: Robot Communication Inspection

Check whether the teach pendant is connected normally and whether there is any alarm signal. Common error situations are as follows:

1. Not connected error Check whether the robot encoder cable is loose and whether the welding machine power supply is turned on.

2. Emergency stop error Check whether the emergency stop switch has been triggered.

3. Singularity error Click “Joint Return to Zero” in the monitoring position, as shown in the figure below.

Caption: Teach pendant interface: monitoring / position menu

Caption: Joint Return to Zero interface

Image annotation translations:

• Position

• Monitoring

• Joint Return to Zero

Step 3: Ground Wire Inspection

Confirm that the ground wire is connected normally and is not loose, in order to prevent equipment overcurrent, electrical leakage, unstable welding current and voltage, and other situations.

Caption: Ground wire connected to the workpiece

Image annotation translation:

• Workpiece connection point

Step 4: Welding Gas Inspection

Check whether the gas cylinder has sufficient gas, whether the gas hose is leaking, whether the gas type is consistent with the welding process, and whether gas comes out from the welding torch head. Use the teach pendant to test gas output.

Caption: Welding machine gas connection point

Caption: Teach pendant / gas test reference interface

Image annotation translation:

• Welding machine connection point

Step 5: Confirm the Parking Position of the Tracked Trolley

Confirm that the parking position is level, that there are no obstacles under the rail, and that no metal object is connected to the workpiece, in order to prevent overcurrent. The ground wire is excluded.

Caption: Gas cylinder pressure gauge

Image annotation translation:

• Air pressure gauge. If the value is below 5, check whether there is no gas.

Step 6: Support Device Inspection

Check whether the trolley support legs are fully retracted or extended as required, and confirm that the vehicle body is stable. The trolley has three support points in total: two on the outer side and one on the inner side.

Caption: Trolley support leg / support wheel

Image annotation translation:

• Support wheel

II. Tracked Trolley Operating Procedures

Step 1

Turn on the power switch, observe whether the indicator light turns on, and confirm that the system self-check has passed, as shown in the figure below.

Caption: Trolley power and battery display panel

Image annotation translations:

• Main power switch

• Robot power switch

• Trolley power switch

• Battery switch

• Battery level display

• Trolley power display

Step 2: Movement Operation

Use the forward and backward buttons on the remote control to move the trolley.

Step 3: Steering Operation

Use the steering button to adjust the direction. The forward button and the steering button must not be pressed at the same time.

Step 4: Trolley Support Operation

After reaching the working position, extend the support legs to fix the vehicle body. Before moving the trolley, retract the support legs.

Note: It is forbidden to move the trolley before the support legs are retracted, in order to avoid damaging the support structure.

Caption: Remote control panel for trolley movement and support legs

Image annotation translations:

• Outer support extension/retraction
• Exit
• Inner support extension/retraction
• Start
• Press and hold the switch
• Stop
• Forward/backward key
• Speed
• Steering button
• Low speed
• Emergency stop
• Throttle minimum
• Menu
• Throttle maximum

III. Software Operating Procedures

Step 1

Open the operating software.

Caption: Software desktop icon

Image annotation translation:

• Software desktop icon

Step 2

Double-click to open the operating software, as shown in the figure above.

Click “Connect” and confirm that the robot and vision system are connected normally, as shown in the figure below.

Caption: Connection interface: robot and vision system connected normally

Image annotation translations:

• One-click connection

• Reverse modeling

• Extract weld seam

• Start welding

• Stop all

• Robot connected

• Small camera connected

• If all indicators are green, the connection is normal.

Step 3

Perform reverse modeling. After the modeling is completed, the point cloud will appear, as shown in the figure below.

Caption: Point cloud display after reverse modeling

Image annotation translations:

• Reverse modeling

• Point cloud display

Step 4

Double-click the right mouse button and select “Global Drawing,” as shown in the figure below.

Caption: Global Drawing / operation mode selection pop-up window

Pop-up window translation:

• Select View Template Operation Mode
• Line direction calibration — laser line scanning calibration
• Please select an operation mode
• Model point selection — select points from the model
• Trajectory Mode — default offline state
• Box-select XY range — use the mouse to select points
• Model-based positioning point selection — based on model positioning
• Box-select Z range — use the mouse to select points
• Global weld point drawing — select points within the global range
• Confirm
• Create node — create a new operation node
• Cancel

Step 5

Draw the lines in sequence according to the arrows marked in the figure, as shown in the figure below.

Caption: Line drawing sequence according to marked arrows

Step 6

After line drawing is completed, right-click the mouse. A pop-up window will appear. Fill in the required task template, as shown in the figure below.

Caption: Enter the node task template

Image annotation translation:

• Enter the node task template

Step 7

In the template, select the node corresponding to this workpiece. Then click “Confirm,” and welding can be started.

Caption: Start welding task interface

Image annotation translations:

• Start welding for all tasks

• Single-task welding

Special Notes

I. If Node Parameters or Welding Process Parameters Need to Be Modified, Follow the Procedure Below

1. Open the template in the “Common” module of the software, as shown in the figure below.

Caption: Open the template in the Common module

Image annotation translation:

• Common

2. Select the same template as the task used during line drawing, and modify the node parameters inside it, as shown in the figure below.

Caption: Select the task template

Image annotation translation:

• Select task

3. Select the node.

Caption: Select node interface

Image annotation translation:

• Select node

Caption: Node selection / save confirmation interface

4. Modify the welding process parameters.

Caption: Node and welding path parameter interface

Caption: Welding process parameter editing reference diagram

Image annotation translations:

• Node parameter editing
• H1 to H2 are the vertical welding height.
• Select node
• W is the upper flat-weld length.
• Modify welding process parameters. These correspond to the 8 vertical welding parameters and 8 flat welding parameters in the process package.
• R1 and R2 are the arc transition values from vertical welding to flat welding.
• Parameters d1 to d4 are weld access holes.
• b1 and b2 are the bottom flat-weld length.
• H is the height of the scanning transition point.
• Other values are fixed.

IV. Common Problems and Solutions

1. Software Connection Failure or Workstation Not Switched Over

Solution:

Check whether the teach pendant is in AUTO mode and whether the teach pendant has any alarm. Then connect again and manually switch the workstation, as shown in the figure below.

Caption: Software connection failure / workstation not switched over

Image annotation translations:

• Displayed when single-step connection fails

• Manually select workstation switching. Here it is PCS3.

2. Trolley Remote Control Does Not Respond

Solution:

The power supply is not turned on, or the remote control is in a low-battery state. The remote-control battery level may appear unstable. Recharge the remote control to solve the problem.

3. Unable to Operate the Mobile Robot in the Software

Solution:

The tool/workstation switching is abnormal. Check whether either the tool or the workstation has switched to 0. If so, disconnect and reconnect the system to solve the problem, as shown in the figure below.

Caption: Check whether the task value is 0

Caption: Disconnect first, then reconnect

Image annotation translations:

• Check whether the task value is 0. If it is 0, switch again and reconnect.

• Disconnect first, then reconnect.

V. Supplementary Notes

1. This procedure must be used together with actual on-site operation training.