Industrial Automation and Robotics

Robotics is one of the most exciting fields that has potential applications in today’s world. Everything from parking a car to industrial automation to a rocket can be automated using robots and other software. The introduction of robotics as a dedicated field changed our vision of the world to a much more technologically advanced one.

Robotics is a very diverse field with numerous applications. Appliances such as self-opening doors and packaging lines use robotics to improve the way they operate. Robots are being used in several fields, from manufacturing to medical sciences. One of the most interesting applications of robotics is industrial automation.

Factory Automation Robotics
Factory using robotics on an assembly line

What are Robots?

Read More

National Power Outage Statistics by State

These days, manufacturing is inextricably linked to the power grid. Many manufacturing processes are now automated using increasingly complex software programs and robotic machines that rely on a constant supply of electricity. So when a blackout occurs, more than just the lights go out in a typical factory. Outages can amount to critical failure and gobs of lost revenue for all stakeholders involved.

At MRO Electric, we wanted to find out which U.S. states experience the most and least power outages and electrical downtime. To accomplish that, we collected and analyzed the latest electrical reliability data from the U.S. Energy Information Administration. Specifically, we pulled the average annual frequency and duration of power outages per customer for each U.S. state from 2015 through 2019. Read on to see what we found. 

Read More

A Comprehensive G Code Guide: Discovering Fanuc G Codes and CNC G Code Commands

As a generic name for a plain-text language that CNC machines are able to understand, G-Codes are important to understand in the manufacturing, automation and engineering spaces. You can enter a G-Code manually if you wish, but you do not have to because of the CAD/CAM software’ abilities along with the machine controller.  G-Codes are not necessarily readable by humans, but it’s possible to look through the file and determine what is generally occurring.

What Is G Code?

In the factory automation space, nobody likes downtime and receiving error codes. While using CNCs (view FANUC CNC parts here), many professionals are faced with G Codes. By definition, a G Code is a computer code language that is used to guide CNC machine devices to perform specific motions.

What Do CNC G Codes Do?

G Codes are important because they allow easy, repeatable control of the motion of a CNC machine. A few examples of specific motions that CNC G Codes can control, would be:

  • canned cycles
  • work coordinates
  • several repetitive cycles.

Canned Cycles

Also referred to as a fixed cycle, canned cycles are ways to effectively and efficiently perform repetitive CNC machining operations. They automate specific machining functions. A few examples would be pocketing, threading, and drilling. A canned cycle is almost always stored as a pre-program in a machine’s controller. To learn more about canned cycles, check out this article courtesy of zero-divide.net.

Work Coordinates

The G Code coordinate pipeline goes something like this:

  • Unit conversion to metric
  • Convert from relative to absolute and polar to Cartesian: g90g91XYZ()
  • G52, G54, and G92 offsets
  • G51 scaling
  • G68 coordinate rotation

G-Code is the most popular programming language used for programming CNC machinery. Some G words alter the state of the machine so that it changes from cutting straight lines to cutting arcs. Other G words cause the interpretation of numbers as millimeters rather than inches. Some G words set or remove tool length or diameter offsets. Be sure to check out our article covering FANUC CNC Codes, including FANUC M Codes, here.

MRO Electric and Supply has new and refurbished FANUC CNC parts available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

What Are the Different Types of G Code Commands?

Listed below are some easily-understood G-code commands in which are used for setting the speed, feed, and tool parameters.

F= Feed

The F value in G-code is used to set the feed rate, which determines the speed at which the machine’s extruder or tool head moves. F values are typically measured in millimeters per minute (mm/min), so dividing the F value by 60 converts it to millimeters per second (mm/s). For instance, an F value of F1500 means the feed rate is 25 mm/s. The machine operates at this specified feed rate when a G1 command is used, which is essential for precise control of the movement speed.

It is crucial to set the feed rate (F) before the first G1 command to avoid errors. Here’s an example of setting the feed rate:

  • G1 F1500 X100 Y100

In this example, the machine will move to the coordinates X100 Y100 at a speed of 1500 mm/min (25 mm/s).

S= Spindle Speed

The S command’s purpose is to set the spindle speed. The Spindle speed is almost always set in RPMs (revolutions per minute). Here is an example:

  • S10000

T= Tool

The T command’s purpose is paired with M6 in order to display the tool number to be used for cutting the current file. Here is an example:

  • M6 T1

Common G Code Command List

Below is a comprehensive list of common CNC G Codes, designed to guide you through the essential programming for CNC machines.

  • G00     Rapid traverse 
  • G01     Linear interpolation with feed rate
  • G02     Circular interpolation (clockwise)
  • G03     Circular interpolation (counterclockwise)
  • G2/G3 Helical interpolation
  • G04     Dwell time in milliseconds
  • G05     Spline definition
  • G06     Spline interpolation
  • G07     Tangential circular interpolation, Helix interpolation, Polygon interpolation, Feedrate interpolation
  • G08     Ramping function at block transition / Look ahead “off”
  • G09     No ramping function at block transition / Look ahead “on”
  • G10     Stop dynamic block preprocessing
  • G11     Stop interpolation during block preprocessing
  • G12     Circular interpolation (CW) with radius
  • G13     Circular interpolation (CCW) with radius
  • G14     Polar coordinate programming, absolute
  • G15     Polar coordinate programming, relative
  • G16     Definition of the pole point of the polar coordinate system
  • G17     Selection of the X, Y plane
  • G18     Selection of the Z, X plane
  • G19     Selection of the Y, Z plane
  • G20     Selection of a freely definable plane
  • G21     Parallel axes “on”
  • G22     Parallel axes “off”
  • G24     Safe zone programming; lower limit values
  • G25     Safe zone programming; upper limit values
  • G26     Safe zone programming “off”
  • G27     Safe zone programming “on”
  • G33     Thread cutting with constant pitch
  • G34     Thread cutting with dynamic pitch
  • G35     Oscillation configuration
  • G38     Mirror imaging “on”
  • G39     Mirror imaging “off”
  • G40     Path compensations “off”
  • G41     Path compensation left of the workpiece contour
  • G42     Path compensation right of the workpiece contour
  • G43     Path compensation left of the workpiece contour with altered approach
  • G44     Path compensation right of the workpiece contour with altered approach
  • G50     Scaling
  • G51     Part rotation; programming in degrees
  • G52     Part rotation; programming in radians
  • G53     Zero offset off
  • G54     Zero offset #1
  • G55     Zero offset #2
  • G56     Zero offset #3
  • G57     Zero offset #4
  • G58     Zero offset #5
  • G59     Zero offset #6
  • G63     Feed/spindle override not active
  • G66     Feed/spindle override active
  • G70     Inch format active
  • G71     Metric format active
  • G72     Interpolation with precision stop “off”
  • G73     Interpolation with precision stop “on”
  • G74     Move to home position
  • G75     Curvature function activation
  • G76     Curvature acceleration limit
  • G78     Normalcy function “on” (rotational axis orientation)
  • G79     Normalcy function “off”

Milling Applications

  • G80     Canned cycle “off”
  • G81     Drilling to final depth canned cycle
  • G82     Spot facing with dwell time canned cycle
  • G83     Deep hole drilling canned cycle
  • G84     Tapping or Thread cutting with balanced chuck canned cycle
  • G85     Reaming canned cycle
  • G86     Boring canned cycle
  • G87     Reaming with measuring stop canned cycle
  • G88     Boring with spindle stop canned cycle
  • G89     Boring with intermediate stop canned cycle

Cylindrical Grinding Applications

  • G81     Reciprocation without plunge
  • G82     Incremental face grinding
  • G83     Incremental plunge grinding
  • G84     Multi-pass face grinding
  • G85     Multi-pass diameter grinding
  • G86     Shoulder grinding
  • G87     Shoulder grinding with face plunge
  • G88     Shoulder grinding with diameter plunge
  • G90     Absolute programming
  • G91     Incremental programming
  • G92     Position preset
  • G93     Constant tool circumference velocity “on” (grinding wheel)
  • G94     Feed in mm / min (or inch / min)
  • G95     Feed per revolution (mm / rev or inch / rev)
  • G96     Constant cutting speed “on”
  • G97     Constant cutting speed “off”
  • G98     Positioning axis signal to PLC
  • G99     Axis offset
  • G100   Polar transformation “off”
  • G101   Polar transformation “on”
  • G102   Cylinder barrel transformation “on”; cartesian coordinate system
  • G103   Cylinder barrel transformation “on,” with real-time-radius compensation (RRC)
  • G104   Cylinder barrel transformation with centerline migration (CLM) and RRC
  • G105   Polar transformation “on” with polar axis selections
  • G106   Cylinder barrel transformation “on” polar-/cylinder-coordinates
  • G107   Cylinder barrel transformation “on” polar-/cylinder-coordinates with RRC
  • G108   Cylinder barrel transformation polar-/cylinder-coordinates with CLM and RRC
  • G109   Axis transformation programming of the tool depth
  • G110   Power control axis selection/channel 1
  • G111   Power control pre-selection V1, F1, T1/channel 1 (Voltage, Frequency, Time)
  • G112   Power control pre-selection V2, F2, T2/channel 1
  • G113   Power control pre-selection V3, F3, T3/channel 1
  • G114   Power control pre-selection T4/channel 1
  • G115   Power control pre-selection T5/channel 1
  • G116   Power control pre-selection T6/pulsing output
  • G117   Power control pre-selection T7/pulsing output
  • G120   Axis transformation; orientation changing of the linear interpolation rotary axis
  • G121   Axis transformation; orientation change in a plane
  • G125   Electronic gearbox; plain teeth
  • G126   Electronic gearbox; helical gearing, axial
  • G127   Electronic gearbox; helical gearing, tangential
  • G128   Electronic gearbox; helical gearing, diagonal
  • G130   Axis transformation; programming of the type of the orientation change
  • G131   Axis transformation; programming of the type of the orientation change
  • G132   Axis transformation; programming of the type of the orientation change
  • G133   Zero lag thread cutting “on”
  • G134   Zero lag thread cutting “off”
  • G140   Axis transformation; orientation designation workpiece fixed coordinates
  • G141   Axis transformation; orientation designation active coordinates
  • G160   ART activation
  • G161   ART learning function for velocity factors “on”
  • G162   ART learning function deactivation
  • G163   ART learning function for acceleration factors
  • G164   ART learning function for acceleration changing
  • G165   Command filter “on”
  • G166   Command filter “off”
  • G170   Digital measuring signals; block transfer with hard stop
  • G171   Digital measuring signals; block transfer without hard stop
  • G172   Digital measuring signals; block transfer with smooth stop
  • G175   SERCOS-identification number “write”
  • G176   SERCOS-identification number “read”
  • G180   Axis transformation “off”
  • G181   Axis transformation “on” with not rotated coordinate system
  • G182   Axis transformation “on” with rotated/displaced coordinate system
  • G183   Axis transformation; definition of the coordinate system
  • G184   Axis transformation; programming tool dimensions
  • G186   Look ahead; corner acceleration; circle tolerance
  • G188   Activation of the positioning axes
  • G190   Diameter programming deactivation
  • G191   Diameter programming “on” and display of the contact point
  • G192   Diameter programming; only display contact point diameter
  • G193   Diameter programming; only display contact point actual axes center point
  • G200   Corner smoothing “off”
  • G201   Corner smoothing “on” with defined radius
  • G202   Corner smoothing “on” with defined corner tolerance
  • G203   Corner smoothing with defined radius up to maximum tolerance
  • G210   Power control axis selection/Channel 2
  • G211   Power control pre-selection V1, F1, T1/Channel 2
  • G212   Power control pre-selection V2, F2, T2/Channel 2
  • G213   Power control pre-selection V3, F3, T3/Channel 2
  • G214   Power control pre-selection T4/Channel 2
  • G215   Power control pre-selection T5/Channel 2
  • G216   Power control pre-selection T6/pulsing output/Channel 2
  • G217   Power control pre-selection T7/pulsing output/Channel 2
  • G220   Angled wheel transformation “off”
  • G221   Angled wheel transformation “on”
  • G222   Angled wheel transformation “on” but angled wheel moves before others
  • G223   Angled wheel transformation “on” but angled wheel moves after others
  • G265   Distance regulation – axis selection
  • G270   Turning finishing cycle
  • G271   Stock removal in turning
  • G272   Stock removal in facing
  • G274   Peck finishing cycle
  • G275   Outer diameter / internal diameter turning cycle
  • G276   Multiple pass threading cycle
  • G310   Power control axes selection /channel 3
  • G311   Power control pre-selection V1, F1, T1/channel 3
  • G312   Power control pre-selection V2, F2, T2/channel 3
  • G313   Power control pre-selection V3, F3, T3/channel 3
  • G314   Power control pre-selection T4/channel 3
  • G315   Power control pre-selection T5/channel 3
  • G316   Power control pre-selection T6/pulsing output/Channel 3
  • G317   Power control pre-selection T7/pulsing output/Channel 3

In conclusion, becoming well-versed on CNC G-Codes, along with other codes associated with CNCs is imperative in this day and age. By having up-to-speed knowledge of CNC codes, you could most definitely set yourself apart from the average Joe.

FANUC Controls Alarms

Fanuc Power Supply Alarm Codes – Alpha Series

Recently we had a customer who was working on troubleshooting a FANUC CNC Power Supply alarm that he had on a machine. He was wondering what the different codes stood for, so we wanted to go ahead and list the different alarm codes for this series. These codes apply to power supplies that start with the following prefixes. The “X”s after the H will be numbered, so an example part number is A06B-6087-H130.

A06B-6081-HXXX
A06B-6083-HXXX
A06B-6077-HXXX
A06B-6091-HXXX
A06B-6120-HXXX
A06B-6140-HXXX
A06B-6110-HXXX

Here is a list of the alarm codes for these series of Power Supply Modules.

AL01: The main circuit power module (IPM) has detected am Error (PSM-5.5,-11)
Overcurrent flows into the input of the main circuit (PSM-15 to –30).

AL02: A cooling fan for the control circuit has stopped.

AL03: The Temperature of the main circuit heat sink has risen abnormally.

AL04: In the main circuit the DC voltage (DC Link) has dropped.

AL05: The main circuit capacitor was not recharged within the specified time.

AL06: The Input Power Supply is abnormal (open phase).

AL07: In the main circuit the DC Voltage at the DC link is abnormally high.

Be sure to check out our article covering FANUC CNC Troubleshooting Frequently Asked Questions here.

A06B-6087-H130 alarm codes

For more information or to get a quote on a FANUC power supply, please call 800-691-8511 or email sales@mroelectric.com.

We also provide repair services for FANUC Power Supplies.

Modicon PLC History

Richard E. Morley, also known as Dick, was an American electrical engineer. He was an employee at Bedford and Associates, located in Massachusetts. He is most commonly known for his involvement with the production of the first Programmable Logic Controller (PLC) for General Motors and the Modicon in 1968. General Motors Company, often referred to as GM, is an American multinational corporation that is headquartered in Detroit, Michigan that engineers, manufactures, markets and distributes vehicles and vehicle parts and sells financial services.

Known as an author, educator, influencer and specialized engineer, Morleys’ accomplishments and contributions have earned him numerous awards from families such as ISA (the instrumentation systems and automation society), Inc. Magazine, Franklin Institute, SME (the Society of Manufacturing Engineers), and the Engineering Society of Detroit. SME offers the Richard E. Morley Outstanding Young Manufacturing Engineer Award for outstanding technical accomplishments in the manufacturing space by engineers age 35 and younger.

Schneider Electric currently owns the Modicon brand of PLCs. The PLC has been recognized as a major advancement in the automation space and has had an unprecedented impact on the manufacturing community as a whole. PLCs were designed to replace re-wiring and hard-wired control panels with software program changes when production updates were necessary. Before PLCs came about, several relays, drum sequencers, cam timers and closed-loop controllers were used to manufacture vehicles and vehicle parts. Re-wiring the relays and other necessary components was a very in-depth and costly process, but clearly worth the effort. The Modicon 084 PLC was modeled to be programmed in ‘ladder logic’ which had the look of the schematic diagrams of relay logic it was replacing.  This made the transition to PLCs easier for engineers and other professionals in the manufacturing space.  The automotive industry is still one of, if not the largest users of PLCs today. MRO Electric and Supply has new and refurbished Modicon parts available including the Modicon Quantum series. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

Modicon PLC History

The Modicon PLC Timeline

A few years later, in the 1970’s, dialogue between PLCs came about. Introduced as the first industrial communications network, Modbus was based on a Slave/Master architecture that used messaging to communicate between Modbus nodes. All and all, a lacking standardization made PLC communications a nightmare.

In the  1980’s, General Electric made an effort to regiment the interconnection of devices from several manufacturers with MAP (manufacturing automation protocol). PLC programming software was also created to operate on personal as well as professional computers in order to remove the need for dedicated programming terminals or handheld programmers.

As years have gone on, PLCs have evolved as technology evolves. Nowadays, they include process, motion, and distributed control systems, as well as complex networking. Equivalent to an average, run-of-the-mill desktop computer, PLCs have capacities for data handling storage and impressive processing power.

Kawasaki E3/E7/E9 Controllers

Being a leader of the robotics industry for over 50 years, Kawasaki has developed one of the most complete lines of e-controllers on the market. All of these controllers are suited with a wide array of features including:

  • High powered CPU performence
  • Large, easy to use LCD Display
  • Optimized key layout
  • Easily accessible safety switches

The E76/77 family of controllers are very compact and used for smaller robot arms. One of these arms are the RS003N Robot, which has a maximum payload of 3kg and has horizontal and vertical reaches of 620mm and 967mm, respectively. The controllers with these robots specialize in assembly and material handling applications.

The E9 family of robotic teach pedants are also built very compact, however these devices are typically used in medium-duty applications. Unlike the other two families of controllers, the E9 family features an open structure system with a direct cooling system. However, like the E7 and E3 families, the enclosed structure with indirect cooling is an available option. The E9 family takes full advantage of the digital servo drive powering it to have a maximum payload capacity of 40kg.

E30/32/33/34 controllers at their base are very alike the E76/77 controllers but with more power. These devices are not as compact as the previous devices we have discussed, however the reason being they are highly expandable and are easier to maintain. Features such as Kawasaki’s K-Logic sequencer software allow the addition of up to 16 total controllable axes. The E3 family of Kawasaki e-controllers are able to handle the following maximum payloads:

  • E30 – 145 kg
  • E32 – 180 kg
  • E33 – 195 kg
  • E34 – 180 kg

If you are interested in learning how to purchase the robot arm, the controller, or any other part/device that goes into an industrial robotic set-up, please call MRO Electric and Supply at (800)691-8511 or email us at sales@mroelectric.com and we will help you get what you need.

3HAC028357-001

ABB Robotics 3HAC028357-001 Teach Pendant

The 3HAC028357-001 is a modern ABB Robotics Teach Pendant designed to be used with the IRC5 Industrial Robot Control, one of the most popular robotics controls on the market. Also known as the “FlexPendant”, the 3HAC028357-001 is characterized by its clean, color touch screen-based design and 3D joystick for intuitive interaction.

The 3HAC028357-001 TPU (or teach pendant unit) is a hand held operator unit used to perform many of the tasks involved when operating a robot system: running programs, jogging the manipulator, modifying robot programs and so on.

The FlexPendant is designed for continuous operation in harsh industrial environment. Its touch screen is easy to clean and resistant to water, oil and accidental welding splashes.

ABB FlexPendant

The 3HAC028357-001 replaces the legacy 3HAC023195-001 teach pendant.

The standard cost for a new ABB 3HAC028357-001 direct from the manufacturer or authorized distributor is typically in the $6000-7,000 range. MRO Electric is able to supply these pendants at a much lower price point, and we warranty all of our robotics parts for 12 months.

If you would like a free quote on a replacement ABB 3HAC028357-001, please email us at sales@mroelectric.com or call 800-691-8511.