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. |
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:
|
Data Port |
This item indicates the desired input port type. The port types are:
|
Circuit Enable |
This item indicates the circuit enable digital output port type. The port types are:
|
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. WarningBe 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. |
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. |
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. |
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. |