CALMATE MENU SCREENS


CALMATE MENU SCREENS

1.  CALMATE MENU SCREEN

CalMate is an optional enhancement to TCPMate. CalMate calculates the x, y, z, and w, p, r of a new TCP. It also allows you to recover the mastering of one of more robot axes after a motor change or a crash.

Table 1.  CalMate Menu Screen Items

ITEM DESCRIPTION

Current Tool

This item is the UTOOL number and the current tool value.

New Tool

This item indicates the changes to the current tool.

Adjust Mode

This item allows you to select a new TCP.

New TCP Type

This item allows you to select TCP XYZ or TCP XYZWPR information.

Recover Type

This item allows you to select the axes for which you can recover mastering.

Setup

This item allows you to set up motion and I/O parameters.

Touch Plate

This item allows you to set up touch plate parameters and position information.

Orientation

This item allows you to set up the TCP orientation using the single point method.

Data Log

This item displays changes to TOOL frame or master data.

2.  CALMATE SETUP SCREEN

Table 2.  CalMate SETUP Screen Description

ITEM DESCRIPTION

Sensor Type

Values: TOS Wrist, I/O, I/O & TOS, TOS ALL AXES

This item indicates the kind of sensor used for contact detection. The three modes are:
  • TOS Wrist (Torque Observer Sensor on Wrist) - the contact torque will be monitored, and only the observed torque will be used to determine the contact position. This is the default value. When TOS Wrist is selected, no I/O connection is required for contact detection.

  • I/O - the specified I/O will be monitored and only the state of this input will be used to determine the contact position. Use the digital input port for contact detection with I/O. Refer to Digital Port item in this table for more information.

  • I/O & TOS - both torque and I/O will be monitored, and the first one to be detected will be used to determine the contact position.

  • TOS ALL AXES (Torque Observer Sensor, All Axes) - The contact torque will be monitored on all robot axes, and only the observed torque will be used to determine the contact position.

    This is the default value. When TOS ALL AXES is selected, no I/O connection is required for contact detection.

Data Port

This item indicates the desired input port type. The port types are:
  • RDI - Robot Digital Input

  • DI - normal Digital Input

  • WDI - Weld Digital Input

  • WSI - Wire Stick circuit Input The port type that you specify is followed by the desired port number that will go from OFF to ON when contact is detected. The WDI and WSI ports are typically used for arc welding. You will set this item up if you selected either I/O, or I/O & TOS, as the Sensor Type. You do not need to set this up if you selected TOS as the Sensor Type.

Circuit Enable

This item indicates the circuit enable digital output port type. The port types are:
  • RDO - Robot Digital Output

  • DOUT - normal Digital Output

  • WDO - Weld Digital Output

  • WSO - Wire Stick circuit Output The port type that you specify is followed by the desired port number that will be used to enable the I/O detection circuit. The WDO and WSO ports are typically used for arc welding. You will set this item up if you selected either I/O, or I/O & TOS, as the Sensor Type. Set the port number to 0 (zero) if you are not using this feature.

Motion Speed

Default: 50

This item is the positioning speed for CalMate. This value can be increased if cycle time is of great concern, or it can be decreased if vibration or other disturbances cause problems with the TOS.

Fine Speed

Default: 10

This item is the search speed for CalMate. This speed is used for both TOS and I/O searches. The value can be increased if cycle time is of great concern (although increasing the speed will also affect the resultant accuracy and repeatability) , or reduced if vibration or other disturbances cause CalMate to retry excessively.

Search Distance

Default: 50

This item is the maximum distance that CalMate will move while looking for the signal.

Learn Distance

Units: mm

Range: 0.5 – 10.0

Default: 5.0

For“TOS All Axes” method only, there is a short motion before each search to identify dynamic torque values. Learn Distance is the distance in millimeters of this short motion, the direction is determined at the time of the motion.

Learn Speed

Units: mm/sec

Default: 10.0

For“TOS All Axes” method only, this is the speed of the learning motion before each search.

Sensitivity Tolerance

Default: 10

This item is the primary sensitivity tolerance of TOS. It is the rate of change of the disturbance torque. The actual units vary with motor model, gear ratio, and amplifier current, and are affected by tooling length. However, the effect for CalMate is largely independent of these factors and a value of 10 is considered normal operation for typical installations. You should not use a value of less than 10 or misdetections might occur. This value can be increased if false detections occur frequently.

Warning

Be careful when you change this number. Changing the sensitivity tolerance might cause a false detection. This could injure personnel or damage equipment.

Torque Threshold

Units: max. motor torque

Range: 1 to 999

Default: 100

This item is the level of disturbance torque that is used as another means of CalMate detection. The default value of 100 is considered normal operation for typical installations. If increasing the value of Sensitivity Tolerance does not make false detections disappear, then this value should be increased until the false detections disappear; then, reset the value of Sensitivity Tolerance .

Tip Profile

This item is the shape of the tooling that contacts the touch plate.

Tool Z Offset

This item is the distance from the point on the tooling that contacts the plate to the actual TCP. This is used when XYZWPR mode is chosen to adjust the XYZ correction at the TCP properly when there is an orientation change. For spot welding and other applications where the contact point is the actual TCP location, this value should be zero. For Waterjet, arc welding, and other applications where the contact point is above the TCP at the time of contact, this value should be set to the distance from the contact point to the actual TCP.

Data Log Enable

This item enables logging of previous TCP values whenever a TCP update occurs. If set to FALSE, logging is disabled.

Data Log Size

This item is the maximum number of TCP values that are stored in the tool log. When the maximum number is reached, the oldest stored TCP value is removed and the new one takes its place. This data is stored in permanent memory, so larger table sizes take up more space. Each entry takes approximately 40 bytes of permanent memory.

Torque Threshold

Default: 100

This item is the level of disturbance torque that is used as another means of CalMate detection. The default value of 100 is considered normal operation for typical installations. If increasing the value of Sensitivity Tolerance does not make false detections disappear, then this value should be increased until the false detections disappear; then, reset the value of Sensitivity Tolerance .

Tip Profile

This item is the shape of the tooling that contacts the touch plate.

Tool Z Offset

This item is the distance from the point on the tooling that contacts the plate to the actual TCP. This is used when XYZWPR mode is chosen to adjust the XYZ correction at the TCP properly when there is an orientation change. For spot welding and other applications where the contact point is the actual TCP location, this value should be zero. For Waterjet, arc welding, and other applications where the contact point is above the TCP at the time of contact, this value should be set to the distance from the contact point to the actual TCP.

Data Log Enable

This item enables logging of previous TCP values whenever a TCP update occurs. If set to FALSE, logging is disabled.

Data Log Size

This item is the maximum number of TCP values that are stored in the tool log. When the maximum number is reached, the oldest stored TCP value is removed and the new one takes its place. This data is stored in permanent memory, so larger table sizes take up more space. Each entry takes approximately 40 bytes of permanent memory.

3.  CALMATE PLATE SETUP SCREEN

You can set up touch plate parameters and positions from the CalMate Plate SETUP screen.

Table 3.  CalMate Plate SETUP Screen Items

ITEM DESCRIPTION

Plate

This item is the plate number.

Plate Axis

This item indicates the axis perpendicular to the touch plate. A normal installation is WORLD z, where -z motion from the home reference position will cause the tool to go through the touch plate circle.

Plate Thickness

This item is the thickness (in mm) of the touch plate.

Entry TPE Name

This item indicates an optional program that can be run prior to CalMate motion.

Orientation count

This item is the number of orientations as specified in Angle 1 through 5.

Angle 1 - 5 : (degree)

This item is the amount of rotation at the TCP for the current iteration.

Center Approach

This item is the position above the hole in the touch plate.

Center Pos 1

This item is the position inside the hole where motion will cause contact near the TCP.

Center Pos 2

This item is the position inside the hole further along the shank used to set the tool orientation.

Plate Approach

This item is the position above the flat surface of the plate.

4.  CALMATE ORIENTATION SCREEN

You can set the tool orientation from the CalMate Orientation screen.

Table 4.  CalMate Orientation Screen Items

ITEM DESCRIPTION

Current Orientation

This item shows the actual orientation of the TCP, before Auto TCP has calculated a TCP.

New Orientation

This item shows how you want the TCP to be oriented after Auto TCP has calculated a TCP.

Reference Position

This item specifies the location within the UTOOL frame where the orientation of the TCP will originate.

5.  CALMATE DATA LOG SCREEN

The data log is a buffer that holds previous tool frame information. The buffer can hold up to as many items as are specified in the CalMate setup menu. When the buffer is full, it will replace the oldest data in the buffer with the new logged data.

Table 5.  CalMate Data Log Screen Items

ITEM DESCRIPTION

Date

This item is the date the data was saved.

Time

This item is the time the data was saved.

X(W)

This item indicates the X(W) or J1(J4) mastering data position information.

Y(P)

This item indicates the Y(P) or J2(J5) mastering data position information.

Z(R)

This item indicates the Z(R) or J3(J6) mastering data position information.