OVRS-2 Common Robot Rules of Process Specification

Automation
OVRS-2
OV Common Robot Rules of Process
Version 1.0
März 2018
Opel Automobile GmbH
OV ME Strategy
Author(s):
Vanessa Braum — OV / Body Automation Robotics Execution
Fernando de Pablo — OV / Body Automation Robotics Execution
Forward questions and comments to:

Bahnhofsplatz I
Mail Code IPC 42-74
D-65423 Ruesselsheim am Main
Vanessa Braum
Document revisions:
Date Revision By Revision history
2018-02 1.0 Vanessa Braum Robot Rules of Process Specification
März 2018 OVRS-2 1 of 11

Version 1.0 General OVRS-2 Common Robot Rules of
Process Specification.docx
OV ME Strategy
Table of Contents
1 GENERAL ................................................................................................................................. 3
1.1 Scope ...................................................................................................................................................................... 3
1.2 Purpose................................................................................................................................................................... 3
2 NORMATIVE REFERENCES .................................................................................................... 3
3 ROBOTIC SAFETY ISSUES ..................................................................................................... 3
4 PAYLOAD ANALYSIS AND ROBOT SELECTION ................................................................ 3

4.1 Robot payload analysis........................................................................................................................................ 3
4.2 Robot supplier selection ...................................................................................................................................... 3
5 ROBOTIC CELL TIMING BEFORE SIMULATION.................................................................. 4

5.1 Robot quantity ...................................................................................................................................................... 4
5.1.1 Robot quantity calculation rule for respot lines ........................................................................................ 4
5.1.2 Robot quantity per cell............................................................................................................................... 4
5.2 Rough cycle time rules .......................................................................................................................................... 4
5.2.1 Respot robots ............................................................................................................................................. 4
5.2.2 Framing or geo-set robots ......................................................................................................................... 4
5.3 MH and Ped welding robots ................................................................................................................................ 5
5.4 Carried stud welding robots ................................................................................................................................ 5
5.5 Carried dispense processing rules...................................................................................................................... 6
5.6 Carried arc welding robots.................................................................................................................................. 6
5.7 Projection nut welding robots ............................................................................................................................. 6
5.8 Clinch nut welding robots..................................................................................................................................... 6
5.9 Tool changer timing .............................................................................................................................................. 6
5.10 Robotic Racking .................................................................................................................................................... 6
6 ROBOT RULES OF PROCESS ................................................................................................. 6

6.1 Robot reach ........................................................................................................................................................... 6
6.2 Home and pounce ................................................................................................................................................. 6
6.3 Robot clearances and tip wear ........................................................................................................................... 7
6.4 End-effector mounting ......................................................................................................................................... 7
6.5 Weld spot distribution requirements ................................................................................................................. 8
6.6 Tip dressers............................................................................................................................................................ 8
6.7 Robot control ......................................................................................................................................................... 8
6.8 Process/function limits .......................................................................................................................................... 8
6.8.1 Two process rule ......................................................................................................................................... 8
6.8.2 Material handling valves, clamps, part present switches and vacuum pumps ...................................... 11
6.9 Tool changers ...................................................................................................................................................... 11

OV ME Strategy
1 General
1.1 Scope
This document provides OV engineering groups and suppliers with robotic processing standards that
promote proper robot utilization and extend the life of robots, robot dress and other associated
equipment.
This document primarily focuses on body shop applications at this time.
The “Rules of Process” were developed to ensure common application of the standard interface in
the processing of robots. These rules are based on the limitations of both the common interface
design and a typical industrial robot.
1.2 Purpose
The processing standards outlined in this specification shall be adhered to in order to achieve
common solutions.
This specification is intended to guide robotic simulation operators and process engineers in the
standardization of processing and designing robot applications for OV.
2 Normative references
The following standards contain provisions that, through reference in this text, constitute part of the
enclosed documentation. The Machinery Directive, its harmonized standards and the regulations of
the respective country shall be adhered to.
This version of OVRS-2 applies to programs that are still in the processing phase during or after July
2006. Programs that have been processed before this time can stay with the previous version of
SKRs.
3 Robotic safety issues

All safety requirements must be followed in the design and layout of a robotic application as
according to the Machinery Directive, its harmonized standards and the regulations of the
respective country, and it will be referenced for any design-in safety buyoff procedure
4 Payload analysis and robot selection
4.1 Robot payload analysis

During the early design of robot carried tooling, the payload shall be analyzed to determine the
correct robot size. Payload analysis rules are found in the current version of GMD-1 (Global
Mechanical Design Standards) section 20.8.
4.2 Robot supplier selection

The OV robotics engineer will know which robot supplier will be used on a project.

OV ME Strategy
5 Robotic cell timing before simulation

5.1 Robot quantity
5.1.1 Robot quantity calculation rule for respot lines
Use the robot quantity calculation rule when an initial rough estimate of the quantity of robots is
required. This is only an initial estimate.
(Total # Weld Spots) X (2 sec/spot)
Total # of Robots
(Available Weld Time – 5 sec) X (Weld Time Utilization)
Where,
Total # of Weld Spots = the total number of weld spots estimated for that line
Available Weld Time = the maximum available time for a robot to weld
Weld Time Utilization Ratio* = the ratio of total robot processed weld time to total robot available
weld time
* Note: The Weld Time Utilization Ratio for calculating the quantity of robots will be defined per
project
5.1.2 Robot quantity per cell

See “PLC Span of Control” under “Architecture” of OVCH.
5.2 Rough cycle time rules

Use this rough cycle time calculation rule when little is known about the product or the tooling in the
robot’s path. This rule does not replace robot simulation cycle times.
5.2.1 Respot robots

Rough Cycle Time = 2.5 sec in + (# of Weld Spots X 2sec/spot) + 2.5 sec out
Where, # of Weld Spots = the number of weld spots planned for that robot
5.2.2 Framing or geo-set robots

Rough Cycle Time = 2.5 sec in + (# of Weld Spots X 3sec/spot) + 2.5 sec out
Where, # of Weld Spots = the number of weld spots planned for that robot
Example
Assume an engineer is analyzing a respot robot application where it is uncertain if the robot will have
to reorient in order to get the estimated 12 welds. Also, the product data is not well defined. The
cycle time for that robot should be calculated as follows:
Rough Cycle Time = 2.5 sec in + (12 Spots X 2sec/spot) + 2.5 sec Out = 29 sec

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5.3 MH and Ped welding robots

Use the rough cycle time rule for MH robots when little is known about the product or end-effector
design. This estimate is rough and does not replace simulation.
Rough Cycle Time = 6 to 9 sec **pick & clear + (# of Weld Spots X 2 sec) + 6 to 9 sec **drop & clear
* Home I/O (housekeeping) delay = 3.0 sec for ABB and Fanuc RJ-2, 1.5 sec for Fanuc RJ-3, R2000 and
Kuka
** Pick/drop: Large part like Floor pan, roof, hood, MC Rail = 9 sec. Small part = 6 sec. Pick and clear
or drop and clear can range from 6 to 9 sec based on carried part size. The smallest parts can clear
the tool faster while the largest parts, like floor pans and hoods, take the longest.
Example
Assume an engineer is analyzing a robot application where a Fanuc RJ3 robot will carry a long narrow
part like a Tie Bar. The end-effector orientation is such that the robot travel to the tool is less than it
would be with a wide part. The robot will use 7 sec (in the range of 6 – 9 sec) to pick & clear. The robot
has 12 Ped welding spots to do. The cycle time for this robot should be calculated as follows:
Rough MH Cycle Time = 7sec Pick & Clear + (12 Ped Spots X 2sec) + 7sec Drop & Clear = 38sec
5.4 Carried stud welding robots

Use the stud weld cycle time calculation rules to estimate the cycle time of a stud weld robot. It is
important to use the correct formula based on the type of stud being applied by the robot.
Stud Weld Cycle Time = 2.5 sec In + (# of Studs X [SWT + .5 per move]) + 2.5 sec Out
Where: (# of Studs) = Number of stud welds for that robot.

And: (SWT) = Stud Weld Time for that type of stud as found on
Standards_Library/simulation/index.htm
And: .5 sec per move between studs for studs within a few inches on the same plane.
Example
Assume an engineer is analyzing a robot carried stud weld application where the robot will have an
estimated 8 stud welds of type M6x25mm, which welds take 2.2 sec as found on
The cycle time for that robot should be calculated as follows:
Stud Weld Robot Cycle Time = (2.5 sec in) + (8 Studs X (2.2 + .5) sec) + (2.5sec Out) = 25.6 sec

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5.5 Carried dispense processing rules

Processing rule: Utilize this cycle time calculation to determine:
1. An estimate of the length of the dispensing process based on the available cycle time
2. An estimate of the process cycle time based on the given length of dispensing process
Rough Cycle time = # of beads * [(2.5 sec In) + (Bead Length in mm + *200 mm per bead) / (Robot
speed in mm/sec) + (2.5 sec Out)]
*200 mm per bead is 100 mm before and 100 mm after each continuous bead to account for sticky
dispense material and line straightening. See section on
for dispense robot speed settings.
Note: The information indicated for early processing are only rough estimates. A detailed simulation
will give a more accurate time estimate.
5.6 Carried arc welding robots

Rough Cycle time = 2.5 sec in + (0.6 sec Arc start) + (Bead Length in mm) / (Robot speed in mm/sec) +
(.6 sec End fill delay)] + (2.5 sec return to Home)
5.7 Projection nut welding robots

Rough Cycle time = 2.5 sec in + (# Weld Spots X 3 sec/spot) + (2.5 sec out)
5.8 Clinch nut welding robots

Rough Cycle time = 2.5 sec in + (# Weld Spots X 2 sec/spot) + (2.5 sec out)
5.9 Tool changer timing

Tool Changer = (0.3 sec unlatch) + (0.3 sec latch) + (0.6 sec concurrent with return to home motion
As a guideline in early processing, 12 seconds can be used to estimate the total time to exchange
tools.
5.10 Robotic Racking

Reference: Robotic Racking OVRS-3U1
6 Robot rules of process
6.1 Robot reach
Each robot shall be placed in simulation, and called out in the system layout, such that the actual
robot can be misplaced on the floor by up to 100 mm in any direction and still be able to reach all of
its spots.
6.2 Home and pounce

The home and pounce positions should be programmed as close to the work as possible without
interference with moving material or tooling. Pounce should be a unique position from home but very
close, if possible, in order to save cycle time.

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6.3 Robot clearances and tip wear

Clearances between the gun shanks and product while welding or in motion shall be greater than 5
mm before and after tip wear. The amount of tip wear to set up clearance checks in tool design and
simulation is 5 mm per tip. (See Figure 6.3-1: Tip Wear Clearance: Tip Wear Clearance) Clearances
between robot carried parts, including dress, and stationary parts shall be greater than 10 mm,
unless there is a functional need to come in contact. Clearances between two robots or any of their
attachments shall be greater than 20 mm. A robot could be misplaced by 100 mm and would still
need the required clearance. Clearance between tips and product is called out in GWS-1A.
Figure 6.3-1: Tip Wear Clearance
6.4 End-effector mounting

When determining how the end-effector (including the weld gun. stud gun and dispense gun) is
mounted to the face plate of the robot, the end-effector shall be mounted such that:
1. It is square to the base of the robot when the robot’s joints are centered at (zero degrees) synch
position, minimizing the need for angle brackets.
2. While the robot is running its path, joint 5 has a bend in it (near 90 degrees is preferred) to avoid
singularities whenever possible. Avoid key positions where joint 5 must be near zero degrees. (ex., at
spot welds, while dispensing, pick, drop, tip dressing, etc.)
3. There is as little rotation as possible from the robot’s home position to the position where the joint
angles of the robot are at zero degrees—also taking items 1 and 2 above into account.
4. The CG is as close as possible to the centerline and surface of the robot’s faceplate.
5. Joints 4 and 6 should be centered rather than turned one way at home position and during its
motion, if possible. This method of programming will help when synchronizing the robot.

OV ME Strategy
6.5 Weld spot distribution requirements

Weld spots are grouped by gun orientation due to robot dress and equalization issues.
• Minimize weld gun rotation.

• Avoid flipping guns upside down because of equalization and gravity.
• The robot shall weld on no more than two grossly different weld planes, where the angle difference is
greater than 45 degrees.
Follow these in order to achieve an acceptable robot process:
• Redistribute weld spots among robots

• Modify robot path in simulation
• Change the weld gun bracket
• Change the weld gun tip configuration
• Change the weld gun
6.6 Tip dressers

The following tip dress parameters shall be followed while placing tip dressers in a cell in which the
weld gun is carried by the robot. The tip dresser shall be placed in simulation following these
parameters:
• The weld gun orientation at the tip dress position shall be approximately the same as the orientation
utilized when welding to facilitate weld gun equalization.
• While moving to the tip dress location, the robot shall be clear of the line transferring in order for the
robot to tip dress while the line is transferring. • While moving to the tip dress location, the robot
shall be clear of the other robots’ paths (i.e., no interference zones in the tip dress path).
• One tip dresser per robot with carried gun.
6.7 Robot control

The sharing of process-related devices, controlled by a robot, is not permitted.
Example: A ped welder controlled by one robot and being used by a second robot.
6.8 Process/function limits

6.8.1 Two process rule
A robot shall be limited to two processes. Material handling in conjunction with two processes is
permitted. Material handling is considered a function and not a process. A single end-effector shall
be limited to two functions, such as MH + carried welding.
Please see Table 6.8-1 to see which process combinations are currently supported. Any application
not listed in Table 6.8-1 is currently not supported through the robot setup wizard. Contact your lead
Vehicle Systems Robot Engineer or Commodity Engineer if you wish to deviate from the list to make
sure the application can be setup manually.
The following table lists all of the applications that are currently supported through the robot setup
wizard.

OV ME Strategy
Tabelle 6.8-1 Supported Robot Applications
Spot Welding 1 Weld Controller

Application # Description
1 1 1 Carried Spot Gun
3 2 1 Pedestal Spot Gun
4 3 1 Pedestal with 2 Spot Guns
5 4 2 Pedestals with 1 Spot Gun Each
6 5 1 Carried Spot Gun with Material Handler
Spot Welding 2 Weld Controllers

7 1 1 Pedestal with 2 Spot Guns
8 2 2 Pedestals with 1 Spot Gun Each
9 5 1 Carried Spot Gun & 1 Pedestal Spot Gun
Dispensing Applications 1 Controller

10 1 1 Carried Dispense Nozzle
11 2 1 Pedestal Dispense Nozzle
12 3 1 Carried Dispense Nozzle with Material Handler
Dispensing Applications 2 Controllers

13 1 2 Carried Dispense Nozzles
14 2 2 Pedestals with 1 Dispense Nozzle on each
15 3 1 Carried Nozzle & 1 Pedestal Dispense Nozzle
Stud welding Applications

16 1 1 Carried Stud Gun With Hot Backup - Single Stud Gun Per Slide
2 1 Carried Stud Gun With Hot Backup - Dual Guns One Slide
3 1 Carried Stud Gun Without Hot Backup
17 1 1 Pedestal Stud Gun With Hot Backup
2 1 Pedestal Stud Gun Without Hot Backup
18 1 1 Pedestal with 2 Stud Guns With Hot Backup
2 1 Pedestal with 2 Stud Guns Without Hot Backup
19 1 3 Pedestal Stud Guns Without Hot Backup
20 1 4 Pedestal Stud Guns Without Hot Backup

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Multiple Process Applications

21 1 1 Pedestal Spot Gun & 1 Pedestal Dispense Nozzle
22 1 1 Carried Spot Gun & 1 Pedestal Dispense Nozzle
23 1 1 Carried Spot Gun & 1 Carried Dispense Nozzle
24 1 1 Pedestal Spot Gun & 1 Carried Dispense Nozzle
25 1 1 Pedestal Spot Gun & 1 Pedestal Stud Gun With Hot Backup
2 1 Pedestal Spot Gun & 1 Pedestal Stud Gun Without Hot Backup
26 1 1 Carried Spot Gun & 1 Pedestal Stud Gun With Hot Backup
2 1 Carried Spot Gun & 1 Pedestal Stud Gun Without Hot Backup
27 1 1 Pedestal Stud Gun With Hot Backup & 1 Pedestal Dispense Nozzle
2 1 Pedestal Stud Gun Without Hot Backup & 1 Pedestal Dispense Nozzle
Metal Forming Applications & Processes

28 1 Tandem Press Lines (Auto detect LPT)
29 2 EOL Transfer Press Lines (Auto detect LPT)
30 3 Robotic De-stacking (Auto detect LPT)
31 4 Robotic Racking (Auto detect LPT)
32 5 Automatic Tool Change (Auto detect LPT)
33 6 Manual Tool Change (Auto detect LPT)

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6.8.2 Material handling valves, clamps, part present switches and vacuum pumps
Tabelle 6.8-2 : Number of clamps allowed
Max Max
Preferred Allowed
(All) (2006 Arch)
Valves 3 10
Clamps 6 18
Part present
3 9
switches
Vacuum
pump 2 4
channels
Note:
• Exceeding the preferred number requires ordering additional equipment.
Example: input block, vacuum pump.
• Style detect switches are not required. Style comes from PLC.
• Venturi vacuum valves are preferred.
• Venturi vacuum valves count like the valves in Table 6.8-2.
6.9 Tool changers

The maximum number of tool changer stalls or positions shall be four per robot. The tool changer
stalls may be arranged on single or separate stands.
Servo guns shall be used when spot weld gun changes are required. Cable guns may not be used with
tool changers.
Use tool changers only when absolutely necessary or in a tooling back-up situation.


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März 2018 OVRS-2 1 of 11

2 NORMATIVE REFERENCES .................................................................................................... 3

3 ROBOTIC SAFETY ISSUES ..................................................................................................... 3

4 PAYLOAD ANALYSIS AND ROBOT SELECTION ................................................................ 3

5 ROBOTIC CELL TIMING BEFORE SIMULATION.................................................................. 4

6 ROBOT RULES OF PROCESS ................................................................................................. 6

März 2018 OVRS-2 2 of 11

This document primarily focuses on body shop applications at this time.

3 Robotic safety issues

4 Payload analysis and robot selection

4.1 Robot payload analysis

4.2 Robot supplier selection

März 2018 OVRS-2 3 of 11

5 Robotic cell timing before simulation

5.1.2 Robot quantity per cell

5.2 Rough cycle time rules

5.2.1 Respot robots

5.2.2 Framing or geo-set robots

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5.3 MH and Ped welding robots

5.4 Carried stud welding robots

Where: (# of Studs) = Number of stud welds for that robot.

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5.5 Carried dispense processing rules

5.6 Carried arc welding robots

5.7 Projection nut welding robots

5.8 Clinch nut welding robots

5.9 Tool changer timing

5.10 Robotic Racking

6.2 Home and pounce

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6.3 Robot clearances and tip wear

Figure 6.3-1: Tip Wear Clearance

6.4 End-effector mounting

März 2018 OVRS-2 7 of 11

6.5 Weld spot distribution requirements

• Minimize weld gun rotation.

Follow these in order to achieve an acceptable robot process:

• Redistribute weld spots among robots

6.6 Tip dressers

6.7 Robot control

6.8 Process/function limits

März 2018 OVRS-2 8 of 11

Tabelle 6.8-1 Supported Robot Applications

Spot Welding 1 Weld Controller

Spot Welding 2 Weld Controllers

Dispensing Applications 1 Controller

Dispensing Applications 2 Controllers

Stud welding Applications

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Multiple Process Applications

Metal Forming Applications & Processes

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6.9 Tool changers

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