Table 1. Relation of iRCalibration Options
iRCalibration Software Option | Documentation | Setup | Production (Suitable for Automatic Operation) | Function |
---|---|---|---|---|
Vision TCP Set | iRCalibration Operator's Manual | Initial TCP | n/a | Initial TCP |
Vision Shift | iRCalibration Operator's Manual | Adjust program points | n/a | Adjust program points |
Vision Frame Set | iRCalibration Operator's Manual | Initial User Frame | n/a | Initial user Frame |
Vision Frame Shift | iRCalibration Operator's Manual | Recover User Frame | Maintain User Frame | Recover user Frame |
Vision Mastering | iRCalibration Operator's Manual | Initial mastering (J2–J5) | n/a | Initial mastering (J2–J5) |
TCP Set (formerly TCPCal) | All Setup and Operations Manuals | Initial TCP** | n/a | Initial TCP |
TCP Shift (formerly TCPCal) | All Setup and Operations Manuals | Recover TCP | Maintain TCP | Recover TCP |
Frame Set | All Setup and Operations Manuals | Initial user frame | n/a | Initial user frame |
Frame Shift (formerly CellCal) | All Setup and Operations Manuals | Recover user frame | Maintain user frame | Recover user frame |
Master Set(formerly RobotCal) | All Setup and Operations Manuals | Initial mastering (J2–J5) | n/a | Initial mastering (J2–J5) |
Master Recovery (formerly RobotCal) | All Setup and Operations Manuals | Master recovery | n/a | Recover mastering |
iRCalibration Signature | HandlingTool Setup and Operations Manual | Robot Calibration | n/a | Make robot accurate |
Deflection Compensation | HandlingTool Setup and Operations Manual | Robot Calibration | n/a | Compensate external force |
Table 2. iRCalibration Master Set Schedule Screen Description
ITEM | DESCRIPTION |
---|---|
Robot J1 - J9 |
The calibration for each axis can be enabled or disabled individually. The default values are good for normal operation For robots with all rotary joints, it is recommended that J2, J3, J4, and J5 all be TRUE. As described in the Calibrate TCP and Calibrate UFrame sections, J1 (and J2 for linear J1 robots), and J6 have special considerations. The normal case for mastering recovery is to use the same settings as for initial mastering. If you need to recover J1 and/or J6 (and/or J2 for linear J1 robots) then you must follow the instructions regarding TCP and UFrame. |
Calibration Group Range 1 - 8 Default: 1 |
This item defines the robot group to be calibrated. |
Calibrate TCP True/False Default: True |
This item allows calibration software to solve for the TCP value. Normally Calibrate TCP is TRUE unless you are using a previously accurately calibrated TCP. If Calibrate TCP is TRUE, then the calibration field corresponding to J6 must be false. You can never calibrate or recover both the TCP and J6. For mastering recovery, if UTool has been maintained and is still valid at the time of mastering recovery, then Calibrate UTool can be FALSE and J6 can be TRUE. |
Calibrate UFRAME True/False Default: True |
This item allows calibration software to solve for the user frame. Note that this will make UFRAME be the center of the circle in the calibration plate and will only set uframe XYZ value. Normally, Calibrate UFrame is TRUE unless you are using a previously accurately calibrated calibration plate. If Calibrate UFrame is TRUE, then the calibration field corresponding to J1 must be false. For TopLoaders or other robots with a linear J1 axis then J2 must be false whenever Calibrate UFrame is TRUE You can never calibrate or recover both UFrame and J1. Additionally for robots with a linear J1 axis you can never calibrate or recover both UFrame and J2. Any J1 (and J2 for linear J1 robots) calibration error can be fully corrected by UFrame. If you use iRCalibration Frame Shift to maintain UFrame following iRCalibration Master Set mastering recovery then it is not necessary to recover J1 (and J2 for linear J1 robots). However, if programming causes these axis to move close to their limits then a run-time limit error may occur if these axes are not recovered. If you want to recover J1 (and J2 ror linear J1 robots) then you MUST mount the calibration plate in a fixed location or in a location that can be exactly duplicated at the time of recovery AND the exact UFrame found during initial mastering must be used at the time of recovery. Normally this is done by dedicating a specific UFrame number for mastering and mastering recovery. |
Allowable mean error Units: mm Range: 0.01 - 100 Default: 2.0 |
This item is the maximum allowable mean error for the calibration computation. |
Mean Error Register Range: 0 - 999 Default: 0 |
If the number is greater than 0, the calibration software will write the calibration mean error to the register. |
Max. Error Register Range: 0 - 999 Default: 0 |
If this number is greater than 0, the calibration software will update the calibration maximum error to the register. |
Use Current TCP True/False Default : TRUE |
This item is used for calibration recovery.
|
Table 3. iRCalibration Master Set Detection Schedule Description
ITEM | DESCRIPTION |
---|---|
Sensor Type Values: TOS Wrist, I/O, TOS ALL AXES Default: TOS ALL AXES |
This item indicates the kind of sensor used for
contact detection. The three modes are:
|
Detection Port Values: RI, DI, WDI, WSI |
This item indicates the desired input port type.
The port types are:
|
Sensor Enable Values: RO, DOUT, WDO, or WSO Default: DOUT |
This item indicates the I/O sensor enable digital
output port type. The port types are:
|
Detection Speed Units: mm/sec Range: 1.0 - 100 Default: 10 |
This item is the search speed for contact detection. 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 iRCalibration Master Set to retry excessively. |
Detection Distance Units: mm Range: 1 - 1000 Default: 50 |
This item is the maximum distance that the robot will move while looking for the signal. If no contact is detected within this distance during a search, an error message will be posted. |
Return Speed Units: mm/sec Range: 5 - 5000 Default: 50 |
This item is the search return speed. This speed is used for both TOS and I/O searches. |
Return to Start Default: TRUE |
When this item is set to YES, the robot will move back to the position before it starts the search motion. This item applies to DETECT POINT instructions only. When this item is set to NO, the robot will move back to a distance specified by the next item (Return distance) |
Return Distance Units: mm Range: 1 - 1000 Default: 50 |
When return to start is set to FALSE, the robot will move back to the distance specified. |
Return term type Default: FINE |
This item is the termination type for return motion. |
Air Cut Speed Units: mm/sec Range: 1 - 1000 Default: 100 |
This item is the non-search motion speed. |
Learn Distance Units: mm Range: 0.5– 20.0 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 Range: 0.5 – 50.0 Default: 10.0 |
For “TOS All Axes” method only, this is the speed of the learning motion before each search. |
Sensitivity Units: max. motor torque/sec. Range: 1 - 999 Default: 10 |
This item is the primary sensitivity tolerance of TOS Wrist and is not used for TOS All-Axes. 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 calibration 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 false detections might occur. This value can be increased if false detections occur frequently. WarningBe careful when you change this number. Changing the sensitivity might cause a false detection. This could injure personnel or damage equipment.
|
Torque Threshold Units: max. motor torque Range: 1 to 999 Default: 100 |
For TOS All Axes, this item is the only measure of contact detection. During the learning motion a torque level is memorized and that level plus Torque Threshold must be exceeded for contact to be determined. If false detections are being experienced then this value should be increased. For TOS Wrist, this item is the level of disturbance torque that is used as another means for contact detection. The default value of 100 is considered normal operation for typical installations. If increasing the value of Sensitivity does not make false detections disappear, then this value should be increased until the false detections disappear; then, reset the value of Sensitivity . |
Fit Tolerance Units: mm Range: 0.1 - 100 Default: 1.0 |
For Detect Circle instruction: The robot detects 4 points inside the circle and the calibration software will fit a circle to the 4 detected positions. The fit error is defined as the maximum distance from the 4 points to the circle. If the fitting error exceeds the tolerance, the calibration software will post an error. |
Radius Tolerance Units: mm Range: 0.1 — 100 Default: 1.0 |
The Detect Circle instruction stores the circle's radius during mastering. At run time, if the computed circle radius differs from the stored radius value and difference exceeds the tolerance, the calibration software will post an error. |
Number of Retry Range: 0 - 9 Default: |
If the number of retry is >0, the calibration software will re-run the detect circle instruction if the current circle detection has either a fit error or a radius error. |
Contact Position Register |
If the position register number is any number other than 0, iRCalibration software will copy the contact position to the position register. |
Table 4. Program Creation Screen Items for Standard iRCalibration Master Set Programs
Item | Description |
---|---|
Program Name |
The program name for the iRCalibration Master Set program creation cannot be changed in this menu. It can be changed in the Set Up menu. It is usually of the form “RCAL_G” followed by the group number of the robot being calibrated. The current active jog group is used in determining which group will be used. |
UTool[10]: Uframe[9]: |
iRCalibration Master Set program creation always uses UTool[10], UFrame[9]. Program Defined will appear if the corresponding frame was not previously set; that is, the frame xyzwpr components were all zero. For this case, when you press F2, CREATE, iRCalibration Master Set will set the frames to the identified values. The Uframe and UTool may be different for different robot models. You cannot change the UTool, Uframe, Detection Schedule, or Calibration Schedule number used by Standard iRCalibration Master Set. However, you can edit the generated program to use different Detection or Calibration schedules. You can change the Uframe or UTool number after the program has been created by using the Tool offset or Frame offset utilities. |
User Set will appear if iRCalibration Master Set had previously generated a program for the current group or if the Uframe or UTool were changed by the user. For this case, iRCalibration Master Set will use the current Uframe or UTool and will not change it when the program is generated. | |
Calibration Schedule[10] Detection Schedule[10] |
The iRCalibration Master Set program creation always uses Calibration Schedule[10] and Detection Schedule[10]. |
Table 5. Robot Calibration Program Taught Points
Taught Point | Description |
---|---|
Approach Position 1 | This point must be located such that the robot can move to both Center Position 1 and Approach position 2 without collision. Also, the wrist must be able to rotate freely at this location without collision. |
Center Position 1 | This point must be located on the side of the touch plate that is consistent with the “Plate Direction” setup value. This position should be rotated toward one extreme of orientation about the plate axis. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Rotate Position 1 | This point must be located on the same side of the touch plate as Center Position 1. This position should be rotated toward the other extreme of orientation about the plate axis, but the total rotation must be less than 180 degrees. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Approach Position 2 | This point must be located such that the robot can move to both Center Position 2 and Approach position 1 without collision. Also, the wrist must be able to rotate freely at this location without collision. |
Center Position 2 | This point must be taught on the opposite side of the plate as Center Position 1. This position should be rotated toward one extreme of orientation about the plate axis. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Rotate Position 2 | This point must be located on the same side of the touch plate as Center Position 2. This position should be rotated toward the other extreme of orientation about the plate axis, but the total rotation must be less than 180 degrees. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Orientation position | This point must be taught with the same orientation as Rotate Position 2 but with the tool shaft extending through the touch plate hole. This position defines the orientation of the tool and +Z will extend out from the tool (such as used by waterjet cutting) if the system variable$CB_VARS.$Z_OUT = TRUE, otherwise +Z will go through the tool (such as used by arc welding) if $CB_VARS.$Z_OUT = FALSE. If the Orientation position is the same as Rotate Position 2 or does not extend through the plate by at least 20mm, then the plate vector is used for determining TOOL Z. |
Table 6. Troubleshooting
Problem | Possible Cause | Solution |
---|---|---|
The robot does not detect the Touch Plate for the I/O method. |
I/O was incorrectly set up. |
Verify that the I/O is set up properly. |
Verify that contact with the Touch Plate will cause the specified I/O signal to go ON. Change polarity of the I/O point if necessary. |
||
The Touch Plate or tool is not isolated. |
Verify that either the tool is isolated (for the case of a charged tool) or that the Touch Plate is isolated (for the case of a charged plate) from ground, and that the element that is not charged is grounded electrically. |
|
The tool or Touch Plate surfaces are dirty. |
Verify that both the tool and plate surfaces are clean and free from film. |
|
The robot hits obstacles during rotations. |
There is not enough space around the Touch Plate. |
Touch up the calibration program's position. |
The robot does not always touch the inside of the Touch Plate hole with a cylindrical portion of the tool. |
The shaft is not far enough through the Touch Plate hole. |
Touch up the calibration program's position. |
When is it appropriate to use the I/O method and when is it appropriate to use Torque Observer Sensor (TOS) method? |
There is delicate or compliant tooling. |
Use I/O method if there is delicate or compliant tooling. |
The wrist center is in the same plane as the Touch Plate. |
Use I/O method if the wrist center is to close to or in the same plane as the Touch Plate. If the tool is durable, TOS All Axes can also be used. |
|
The wrist center is directly above the Touch Plate. |
Use I/O method if the wrist center is directly above the Touch Plate. If the tool is durable, TOS All Axes can also be used. |
|
There is a durable tool and a small robot. |
The TOS All Axes method is recommended for small robots when the I/O method is not used. |
|
There is a durable tool and a large robot. |
Use the TOS All Axes method if there is a durable tool. |
|
Large Calibration Error |
Incorrect UFrame or UTool setting |
Make sure that the solve UFrame and solve UTool flags are TRUE unless the UFrame exactly corresponds to the calibration plate location and unless the UTool exactly corresponds to the calibration tool. |
TOS false detections |
Rerun the calibration and watch to confirm the tool touches the calibration plate for every detection. If it does not touch in one or more detections, increase the TOS Tolerance or increase the learning speed and learning distance or reteach the point with a slightly different rotation. |
Table 7. iRCalibration Mastering Schedule Screen Description
ITEM | DESCRIPTION |
---|---|
Robot J1 - J9 |
The calibration for each axis can be enabled or disabled individually. The default values are good for normal operation where initial mastering is performed and for mastering iRCalibration Mastering from the recovery menu. For robots with all rotary joints, it is recommended that J2, J3, J4, and J5 all be TRUE. As described in the Calibrate TCP and Calibrate UFrame sections, J1 (and J2 for linear J1 robots), and J6 have special considerations. The normal case for mastering recovery is to use the same settings as for initial mastering. If you need to recover J1 and/or J6 (and/or J2 for linear J1 robots) then you must follow the instructions regarding TCP and UFrame. |
Calibration Group Range 1 - 8 Default: 1 |
This item defines the robot group to be calibrated. |
Calibrate TCP True/False Default: True |
This item allows calibration software to solve for the TCP value. Normally Calibrate TCP is TRUE unless you are using a previously accurately calibrated TCP. If Calibrate TCP is TRUE, then the calibration field corresponding to J6 must be false. You can never calibrate or recover both the TCP and J6. For mastering recovery, if UTool has been maintained and is still valid at the time of mastering recovery, then Calibrate UTool can be FALSE and J6 can be TRUE. |
Calibrate UFRAME True/False Default: True |
This item allows calibration software to solve for the user frame. Note that this will make UFRAME be the center of the circle in the calibration plate and will only set uframe XYZ value. Normally, Calibrate UFrame is TRUE unless you are using a previously accurately calibrated calibration plate. If Calibrate UFrame is TRUE, then the calibration field corresponding to J1 must be false. For TopLoaders or other robots with a linear J1 axis then J2 must be false whenever Calibrate UFrame is TRUE You can never calibrate or recover both UFrame and J1. Additionally for robots with a linear J1 axis you can never calibrate or recover both UFrame and J2. Any J1 (and J2 for linear J1 robots) calibration error can be fully corrected by UFrame. If you use CellCal to maintain UFrame following iRCalibration Mastering mastering recovery then it is not necessary to recover J1 (and J2 for linear J1 robots). However, if programming causes these axis to move close to their limits then a run-time limit error may occur if these axes are not recovered. If you want to recover J1 (and J2 ror linear J1 robots) then you MUST mount the calibration plate in a fixed location or in a location that can be exactly duplicated at the time of recovery AND the exact UFrame found during initial mastering must be used at the time of recovery. Normally this is done by dedicating a specific UFrame number for mastering and mastering recovery. |
Allowable mean error Units: mm Range: 0.01 - 100 Default: 2.0 |
This item is the maximum allowable mean error for the calibration computation. |
Mean Error Register Range: 0 - 999 Default: 0 |
If the number is greater than 0, the calibration software will write the calibration mean error to the register. |
Max. Error Register Range: 0 - 999 Default: 0 |
If this number is greater than 0, the calibration software will update the calibration maximum error to the register. |
Use Current TCP True/False Default : TRUE |
This item is used for calibration recovery.
|
Table 8. iRCalibration Mastering Detection Schedule Description
ITEM | DESCRIPTION |
---|---|
Sensor Type Values: TOS Wrist, I/O, TOS ALL AXES Default: TOS ALL AXES |
This item indicates the kind of sensor
used for contact detection. The four modes are:
|
Detection Port Values: RI, DI, WDI, WSI |
This item indicates the desired input
port type. The port types are:
|
Sensor Enable Values: RO, DOUT, WDO, or WSO Default: DOUT |
This item indicates the I/O sensor enable
digital output port type. The port types are:
|
Detection Speed Units: mm/sec Range: 1.0 - 100 Default: 10 |
This item is the search speed for contact detection. 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 iRCalibration Mastering to retry excessively. |
Detection Distance Units: mm Range: 1 - 1000 Default: 50 |
This item is the maximum distance that the robot will move while looking for the signal. If no contact is detected within this distance during a search, an error message will be posted. |
Return Speed Units: mm/sec Range: 5 - 5000 Default: 50 |
This item is the search return speed. This speed is used for both TOS and I/O searches. |
Return to Start Default: TRUE |
When this item is set to YES, the robot will move back to the position before it starts the search motion. This item applies to DETECT POINT instructions only. When this item is set to NO, the robot will move back to a distance specified by the next item (Return distance) |
Return Distance Units: mm Range: 1 - 1000 Default: 50 |
When return to start is set to FALSE, the robot will move back to the distance specified. |
Return term type Default: FINE |
This item is the termination type for return motion. |
Air Cut Speed Units: mm/sec Range: 1 - 1000 Default: 100 |
This item is the non-search motion speed. |
Learn Distance Units: mm Range: 0.5– 20.0 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 Range: 0.5 – 50.0 Default: 10.0 |
For “TOS All Axes” method only, this is the speed of the learning motion before each search. |
Sensitivity Units: max. motor torque/sec. Range: 1 - 999 Default: 10 |
This item is the primary sensitivity tolerance of TOS Wrist and is not used for TOS All-Axes. 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 calibration 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 false detections might occur. This value can be increased if false detections occur frequently. WarningBe careful when you change this number. Changing the sensitivity might cause a false detection. This could injure personnel or damage equipment.
|
Torque Threshold Units: max. motor torque Range: 1 to 999 Default: 100 |
For TOS All Axes, this item is the only measure of contact detection. During the learning motion a torque level is memorized and that level plus Torque Threshold must be exceeded for contact to be determined. If false detections are being experienced then this value should be increased. For TOS Wrist, this item is the level of disturbance torque that is used as another means for contact detection. The default value of 100 is considered normal operation for typical installations. If increasing the value of Sensitivity does not make false detections disappear, then this value should be increased until the false detections disappear; then, reset the value of Sensitivity . |
Fit Tolerance Units: mm Range: 0.1 - 100 Default: 1.0 |
For Detect Circle instruction: The robot detects 4 points inside the circle and the calibration software will fit a circle to the 4 detected positions. The fit error is defined as the maximum distance from the 4 points to the circle. If the fitting error exceeds the tolerance, the calibration software will post an error. |
Radius Tolerance Units: mm Range: 0.1 — 100 Default: 1.0 |
The Detect Circle instruction stores the circle's radius during mastering. At run time, if the computed circle radius differs from the stored radius value and difference exceeds the tolerance, the calibration software will post an error. |
Number of Retry Range: 0 - 9 Default: |
If the number of retry is >0, the calibration software will re-run the detect circle instruction if the current circle detection has either a fit error or a radius error. |
Contact Position Register |
If the position register number is any number other than 0, iRCalibration Mastering will copy the contact position to the position register. |
Table 9. Program Creation Screen Items for Standard iRCalibration Master Recovery Programs
Item | Description |
---|---|
Program Name |
The program name for the iRCalibration Master Recovery program creation cannot be changed. It is of the form “RCAL_G” followed by the group number of the robot being calibrated. The current active jog group is used in determining which group will be used. |
UTool[10]: Uframe[9]: |
iRCalibration Mastering program creation always uses UTool[10], UFrame[9]. Program Defined will appear if the corresponding frame was not previously set; that is, the frame xyzwpr components were all zero. For this case, when you press F2, CREATE, iRCalibration Master Recovery will set the frames to the identified values. The Uframe and UTool may be different for different robot models. You cannot change the UTool, Uframe, Detection Schedule, or Calibration Schedule number used by Standard iRCalibration Mastering. However, you can edit the generated program to use different Detection or Calibration schedules. You can change the Uframe or UTool number after the program has been created by using the Tool offset or Frame offset utilities. |
User Set will appear if iRCalibration Master Recovery had previously generated a program for the current group or if the Uframe or UTool were changed by the user. For this case, iRCalibration Master Recovery will use the current Uframe or UTool and will not change it when the program is generated. | |
Calibration Schedule[10] Detection Schedule[10] |
The iRCalibration Master Recovery program creation always uses Calibration Schedule[10] and Detection Schedule[10]. |
Table 10. Robot Calibration Program Taught Points
Taught Point | Description |
---|---|
Approach Position 1 | This point must be located such that the robot can move to both Center Position 1 and Approach position 2 without collision. Also, the wrist must be able to rotate freely at this location without collision. |
Center Position 1 | This point must be located on the side of the touch plate that is consistent with the “Plate Direction” setup value. This position should be rotated toward one extreme of orientation about the plate axis. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Rotate Position 1 | This point must be located on the same side of the touch plate as Center Position 1. This position should be rotated toward the other extreme of orientation about the plate axis, but the total rotation must be less than 180 degrees. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Approach Position 2 | This point must be located such that the robot can move to both Center Position 2 and Approach position 1 without collision. Also, the wrist must be able to rotate freely at this location without collision. |
Center Position 2 | This point must be taught on the opposite side of the plate as Center Position 1. This position should be rotated toward one extreme of orientation about the plate axis. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Rotate Position 2 | This point must be located on the same side of the touch plate as Center Position 2. This position should be rotated toward the other extreme of orientation about the plate axis, but the total rotation must be less than 180 degrees. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Orientation position | This point must be taught with the same orientation as Rotate Position 2 but with the tool shaft extending through the touch plate hole. This position defines the orientation of the tool and +Z will extend out from the tool (such as used by waterjet cutting) if the system variable$CB_VARS.$Z_OUT = TRUE, otherwise +Z will go through the tool (such as used by arc welding) if $CB_VARS.$Z_OUT = FALSE. If the Orientation position is the same as Rotate Position 2 or does not extend through the plate by at least 20mm, then the plate vector is used for determining TOOL Z. |
Table 11. Troubleshooting
Problem | Possible Cause | Solution |
---|---|---|
The robot does not detect the Touch Plate for the I/O method. |
I/O was incorrectly set up. |
Verify that the I/O is set up properly. |
Verify that contact with the Touch Plate will cause the specified I/O signal to go ON. Change polarity of the I/O point if necessary. |
||
The Touch Plate or tool is not isolated. |
Verify that either the tool is isolated (for the case of a charged tool) or that the Touch Plate is isolated (for the case of a charged plate) from ground, and that the element that is not charged is grounded electrically. |
|
The tool or Touch Plate surfaces are dirty. |
Verify that both the tool and plate surfaces are clean and free from film. |
|
The robot hits obstacles during rotations. |
There is not enough space around the Touch Plate. |
Touch up the calibration program's position. |
The robot does not always touch the inside of the Touch Plate hole with a cylindrical portion of the tool. |
The shaft is not far enough through the Touch Plate hole. |
Touch up the calibration program's position. |
When is it appropriate to use the I/O method and when is it appropriate to use Torque Observer Sensor (TOS) method? |
There is delicate or compliant tooling. |
Use I/O method if there is delicate or compliant tooling. |
The wrist center is in the same plane as the Touch Plate. |
Use I/O method if the wrist center is to close to or in the same plane as the Touch Plate. If the tool is durable, TOS All Axes can also be used. |
|
The wrist center is directly above the Touch Plate. |
Use I/O method if the wrist center is directly above the Touch Plate. If the tool is durable, TOS All Axes can also be used. |
|
There is a durable tool and a small robot. |
The TOS All Axes method is recommended for small robots when the I/O method is not used. |
|
There is a durable tool and a large robot. |
Use the TOS All Axes method if there is a durable tool. |
|
Large Calibration Error |
Incorrect UFrame or UTool setting |
Make sure that the solve UFrame and solve UTool flags are TRUE unless the UFrame exactly corresponds to the calibration plate location and unless the UTool exactly corresponds to the calibration tool. |
TOS false detections |
Rerun the calibration and watch to confirm the tool touches the calibration plate for every detection. If it does not touch in one or more detections, increase the TOS Tolerance or increase the learning speed and learning distance or reteach the point with a slightly different rotation. |
Table 12. Calibration Mode Descriptions
Calibration Mode | Description |
---|---|
New XYZWPR | Sets initial TCP xyzwpr |
New XYZ | Sets initial TCP xyz |
Cal-Plate | Sets initial TCP XYZWPR location of a calibration plate mounted on the faceplate. |
Table 13. iRCalibration TCP Set UTOOL Schedule Item Description
ITEM | DESCRIPTION |
Auto Update Default: TRUE |
This item indicates whether iRCalibration TCP Set's UTOOL END instruction will update the corresponding $mnutool or not. If you set Auto Update to TRUE and run the TCP calibration program, the $mnutool will be updated based on the offset. |
Store Offset Default: FALSE |
This item indicates whether or not iRCalibration TCP Set's UTOOL END instruction will update the position register with the TCP offset. |
Tool Z Offset Units: mm Range: – 500.000– 500.000 Default: 0 |
This item is the distance from the point of 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 a tool Z 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. |
Max. XYZ Offset Units: mm Range: 0.1 — 1000 Default: 30.0 |
This item is the distance in mm from the previous TCP to the new TCP for a single correction. If a single correction is larger than the max. XYZ offset, an error message will be posted. If the out DOUT port is not zero, iRCalibration TCP Set will also set the port to ON. |
Max. Orent Offset Units: deg Range: 0.01 — –20 Default: 5 |
This item is the orientation change in degrees from the previous TCP to the new TCP for a single correction. If a single correction is larger than the max. orientation offset, an error will be posted. |
Max. Alignment Offset Units: mm Range: 0 — 500 Default: 10 |
This item is the maximum alignment change allowed in mm from the previous TCP to the new TCP. If the alignment change is greater than the alignment offset, an error will be posted. This item is in effect when the XYZ-Align calibration mode is selected. |
Deviation Register Range: 0 — 999 Default: 0 |
This item indicates the register number where iRCalibration TCP Set will update with the change between the previous TCP and the new TCP. If this item is 0, no update is performed. |
Accum. Register Range: 0 — 999 Default: |
This item is the change between the new TCP and the original mastered TCP. If this item is not 0, iRCalibration TCP Set will update the register with the accumulated deviation value. |
Accumulated Error Enable Default: FALSE |
If this item is TRUE, iRCalibration TCP Set will check the accumulated deviation against the accumulated error threshold. If the deviation is greater than 0, an error will be posted. |
Accumulated Offset Threshold Default: 25 Min = 0 Max = 500mm |
When the Accumulated Offset Threshold is exceeded and the function is enabled, iRCalibration TCP Set will post and ACAL-060, Excessive Accumulated Offset warning. |
Table 14. iRCalibration TCP Set Detection Schedule Description
ITEM | DESCRIPTION |
Sensor Type Values: TOS Wrist, I/O, TOS ALL AXES Default: TOS ALL AXES |
This item indicates the kind of sensor
used for contact detection. The three modes are:
|
Detection Port Values: RI, DI, WDI, WSI Note: AIN is not supported in iRCalibration TCP Set. |
This item indicates the desired input
port type. The port types are:
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 I/O as the Sensor Type. You do not need to set this up if you selected TOS Wrist or TOS All Axes as the Sensor Type. |
Sensor Enable Values: RO, DOUT, WDO, or WSO Default: DOUT |
This item indicates the I/O sensor enable
digital output port type. The port types are:
|
Detection Speed Units: mm/sec Range: 1.0 - 100 Default: 10 |
This item is the search speed for contact detection. 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 iRCalibration TCP Set to retry excessively. |
Detection Distance Units: mm Range: 1 - 1000 Default: 50 |
This item is the maximum distance that the robot will move while looking for the signal. |
Return Speed Units: mm/sec Range: 5 - 5000 Default: 50 |
This item is the search return speed. This speed is used for both TOS and I/O searches. |
Return to Start Default: TRUE |
When this item is set to YES, the robot will move back to the position before it starts the search motion. When this item is set to NO, the robot will move back to a distance specified by the next item (Return distance) |
Return Distance Units: mm Range: 1 - 1000 Default: 50 |
When return to start is set to FALSE, the robot will move back to the distance specified. This function applies to DETECT POINT instructions only. |
Return term type Default: FINE |
This item is the termination type for return motion. |
Air Cut Speed Units: mm/sec Range: 1 - 1000 Default: 100 |
This item is the non-search motion speed. |
Learn Distance Units: mm Range: 0.5– 20.0 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 Range: 0.5 – 50.0 Default: 10.0 |
For “TOS All Axes” method only, this is the speed of the learning motion before each search. |
Sensitivity Units: max. motor torque/sec. Range: 1 - 999 Default: 10 |
This item is the primary sensitivity tolerance of TOS Wrist and is not used for TOS All-Axes. 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 calibration 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 false detections might occur. This value can be increased if false detections occur frequently. WarningBe careful when you change this number. Changing the sensitivity might cause a false detection. This could injure personnel or damage equipment.
|
Torque Threshold Units: max. motor torque Range: 1 to 999 Default: 100 |
For TOS All Axes , this item is the only measure of contact detection. During the learning motion a torque level is memorized and that level plus Torque Threshold must be exceeded for contact to be determined. If false detections are being experienced then this value should be increased. For TOS Wrist , this item is the level of disturbance torque that is used as another means for contact detection. The default value of 100 is considered normal operation for typical installations. If increasing the value of Sensitivity does not make false detections disappear, then this value should be increased until the false detections disappear; then, reset the value of Sensitivity . |
Fit Tolerance Units: mm Range: 0.1 - 100 Default: 1.0 |
For Detect Circle instruction: The robot detects 4 points inside the circle and the calibration software will fit a circle to the 4 detected positions. The fit error is defined as the maximum distance from the 4 points to the circle. If the fitting error exceeds the tolerance, the calibration software will post an error. |
Radius Tolerance Units: mm Range: 0.1— 100 Default: 1.0 |
The Detect Circle instruction stores the circle's radius during mastering. At run time, if the computed circle radius differs from the stored radius value and difference exceeds the tolerance, the calibration software will post an error. |
Number of Retry Range: 0 - 9 Default: 0 |
If the number of retry is >0, the calibration software will re-run the detect circle instruction if the current circle detection has either a fit error or a radius error. |
Contact Position Register Range 0-100 Default 0 |
If the number is non-zero. iRCalibration TCP Set records the contact position to the specified position register. |
Table 15. New TCP Program Points
Position | Description |
---|---|
Approach Position 1 | This position must be located such that the robot can move to both Center Position 1 and Approach position 2 without collision. Also, the wrist must be able to rotate freely at this location without collision. |
Center Position 1 | Center Position 1 must be located on the side of the touch plate that is consistent with the“Plate Direction” setup value. This position should be rotated toward one extreme of orientation about the plate axis. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Rotate Position 1 | Rotate Position 1 must be located on the same side of the touch plate as Center Position 1. This position should be rotated toward the other extreme of orientation about the plate axis, but the total rotation must be less than 180 degrees. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Approach Position 2 | Approach Position 2 must be located such that the robot can move to both Center Position 2 and Approach position 1 without collision. Also, the wrist must be able to rotate freely at this location without collision. |
Center Position 2 | Center Position 2 must be taught on the opposite side of the plate as Center Position 1. This position should be rotated toward one extreme of orientation about the plate axis. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Rotate Position 2 | Rotate Position 2 must be located on the same side of the touch plate as Center Position 2. This position should be rotated toward the other extreme of orientation about the plate axis, but the total rotation must be less than 180 degrees. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Orientation Position | If you select “New-XYZWPR”, you must teach the orientation position with the same orientation as Rotate Position 2 but with the tool shaft extending through the touch plate hole. This position defines the orientation of the tool and +Z will extend out from the tool (such as used by waterjet cutting) if the system variable$CB_VARS.$Z_OUT = TRUE, otherwise +Z will go through the tool (such as used by arc welding) if $CB_VARS.$Z_OUT = FALSE. |
Table 16. iRCalibration TCP Set Fit Errors
Try This |
Description |
Verify that the tool is rigid. |
Worn or damaged tooling components can cause variation in tool repeatability and can cause fit errors. |
Verify the payload setting. |
If the reference position is at an extreme position, improper payload settings can cause increased robot vibration, which affects iRCalibration TCP Set repeatability. |
Check for a loose touch plate. * |
If the touch plate becomes loosened due to improper installation, iRCalibration TCP Set repeatability will be affected. |
Reduce motion speed. * |
Under certain conditions, the default motion speed can cause too much vibration. For best performance, iRCalibration TCP Set uses increased acceleration values. Try lowering the motion speed from the default 100mm/sec to 25 or 50mm/sec. |
Reduce search speed. * |
Under certain conditions, the default motion speed can cause too much vibration. For best performance, iRCalibration TCP Set uses increased acceleration values. Try lowering the search speed from the default 10mm/sec to 5mm/sec. |
Increase the retry count. * |
iRCalibration TCP Set has significant safeguards against getting incorrect TCP corrections. You can increase the retry count from the default of 0 to either 3 or 4 to reduce the occurrence of iRCalibration TCP Set fit errors. |
Increase the radius tolerance. * |
The default radius tolerance of 1.0 mm may not be large enough to allow for the normal variation of some tooling. You can try increasing the radius tolerance from 1.0 mm to 1.5 mm or more as your application allows. |
Increase the fit tolerance.* |
Most iRCalibration TCP Set errors are detected by radius tolerance, but if increasing the radius tolerance does not resolve the problem, you can increase the fit tolerance from 1.0 mm to 1.5mm or more as your application allows. |
If you are using TOS Wrist, increase the sensitivity value. * |
Normally, the default value of 10 is adequate; however, you can increase this value to either 15 or 20. |
If you are using TOS All Axis, increase the torque threshold. * |
Normally, the default value of 100 is adequate. However, if the sensitivity increases have no effect, you can increase this value to 150. |
Check for poor electrical continuity |
If the I/O method is used, and if it relies on electrical continuity, then dirty contact surfaces on either the tool or the calibration plate will result in increased fit errors. |
Table 17. Calibration Mode Descriptions
Calibration Mode | Description |
---|---|
XYZWPR | Recover TCP xyzwpr |
XYZ_Align | Recover tool XYZ and alignment for spot guns. |
XYZ | Recover Tool XYZ |
XY | Recover tool xy |
Z | Recover tool z |
Gripper | Recover gripper location |
Table 18. iRCalibration TCP Shift UTOOL Schedule Item Description
ITEM | DESCRIPTION |
Auto Update Default: TRUE |
This item indicates whether iRCalibration TCP Shift's UTOOL END instruction will update the corresponding $mnutool or not. If you set Auto Update to TRUE and run the TCP calibration program, the $mnutool will be updated based on the offset. |
Store Offset Default: FALSE |
This item indicates whether or not iRCalibration TCP Shift's UTOOL END instruction will update the position register with the TCP offset. |
Tool Z Offset Units: mm Range: – 500.000– 500.000 Default: 0 |
This item is the distance from the point of 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 a tool Z 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. |
Max. XYZ Offset Units: mm Range: 0.1 — 1000 Default: 30.0 |
This item is the distance in mm from the previous TCP to the new TCP for a single correction. If a single correction is larger than the max. XYZ offset, an error message will be posted. If the out DOUT port is not zero, iRCalibration TCP Shift will also set the port to ON. |
Max. Orent Offset Units: deg Range: 0.01 — –20 Default: 5.0 |
This item is the orientation change in degrees from the previous TCP to the new TCP for a single correction. If a single correction is larger than the max. orientation offset, an error will be posted. |
Max. Alignment Offset Units: mm Range: 0 — 500 Default: 10 |
This item is the maximum alignment change allowed in mm from the previous TCP to the new TCP. If the alignment change is greater than the alignment offset, an error will be posted. This item is in effect when the XYZ-Align calibration mode is selected. |
Deviation Register Range: 0 — 999 Default: 0 |
This item indicates the register number where iRCalibration TCP Shift will update with the change between the previous TCP and the new TCP. If this item is 0, no update is performed. |
Accum. Register Range: 0 — 999 Default: |
This item is the change between the new TCP and the original mastered TCP. If this item is not 0, iRCalibration TCP Shift will update the register with the accumulated deviation value. |
Accumulated Error Enable Default: FALSE |
If this item is TRUE, iRCalibration TCP Shift will check the accumulated deviation against the accumulated error threshold. If the deviation is greater than 0, an error will be posted. |
Accumulated Offset Threshold Default: 25 Min = 0 Max = 500mm |
When the Accumulated Offset Threshold is exceeded and the function is enabled, iRCalibration TCP Shift will post and ACAL-060, Excessive Accumulated Offset warning. |
Table 19. iRCalibration TCP Shift Detection Schedule Description
ITEM | DESCRIPTION |
Sensor Type Values: TOS Wrist, I/O, TOS ALL AXES Default: TOS ALL AXES |
This item indicates the kind of
sensor used for contact detection. The three modes are:
|
Detection Port Values: RI, DI, WDI, WSI Note: AIN is not supported in iRCalibration TCP Shift. |
This item indicates the desired
input port type. The port types are:
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 I/O as the Sensor Type. You do not need to set this up if you selected TOS Wrist or TOS All Axes as the Sensor Type. |
Sensor Enable Values: RO, DOUT, WDO, or WSO Default: DOUT |
This item indicates the I/O sensor
enable digital output port type. The port types are:
|
Detection Speed Units: mm/sec Range: 1.0 - 100 Default: 10 |
This item is the search speed for contact detection. 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 iRCalibration TCP Shift to retry excessively. |
Detection Distance Units: mm Range: 1 - 1000 Default: 50 |
This item is the maximum distance that the robot will move while looking for the signal. |
Return Speed Units: mm/sec Range: 5 - 5000 Default: 50 |
This item is the search return speed. This speed is used for both TOS and I/O searches. |
Return to Start Default: TRUE |
When this item is set to YES, the robot will move back to the position before it starts the search motion. When this item is set to NO, the robot will move back to a distance specified by the next item (Return distance) |
Return Distance Units: mm Range: 1 - 1000 Default: 50 |
When return to start is set to FALSE, the robot will move back to the distance specified. This function applies to DETECT POINT instructions only. |
Return term type Default: FINE |
This item is the termination type for return motion. |
Air Cut Speed Units: mm/sec Range: 1 - 1000 Default: 100 |
This item is the non-search motion speed. |
Learn Distance Units: mm Range: 0.5– 20.0 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 Range: 0.5 – 50.0 Default: 10.0 |
For “TOS All Axes” method only, this is the speed of the learning motion before each search. |
Sensitivity Units: max. motor torque/sec. Range: 1 - 999 Default: 10 |
This item is the primary sensitivity tolerance of TOS Wrist and is not used for TOS All-Axes. 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 calibration 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 false detections might occur. This value can be increased if false detections occur frequently. WarningBe careful when you change this number. Changing the sensitivity might cause a false detection. This could injure personnel or damage equipment.
|
Torque Threshold Units: max. motor torque Range: 1 to 999 Default: 100 |
For TOS All Axes , this item is the only measure of contact detection. During the learning motion a torque level is memorized and that level plus Torque Threshold must be exceeded for contact to be determined. If false detections are being experienced then this value should be increased. For TOS Wrist , this item is the level of disturbance torque that is used as another means for contact detection. The default value of 100 is considered normal operation for typical installations. If increasing the value of Sensitivity does not make false detections disappear, then this value should be increased until the false detections disappear; then, reset the value of Sensitivity . |
Fit Tolerance Units: mm Range: 0.1 - 100 Default: 1.0 |
For Detect Circle instruction: The robot detects 4 points inside the circle and the calibration software will fit a circle to the 4 detected positions. The fit error is defined as the maximum distance from the 4 points to the circle. If the fitting error exceeds the tolerance, the calibration software will post an error. |
Radius Tolerance Units: mm Range: 0.1— 100 Default: 1.0 |
The Detect Circle instruction stores the circle's radius during mastering. At run time, if the computed circle radius differs from the stored radius value and difference exceeds the tolerance, the calibration software will post an error. |
Number of Retry Range: 0 - 9 Default: 0 |
If the number of retry is >0, the calibration software will re-run the detect circle instruction if the current circle detection has either a fit error or a radius error. |
Contact Position Register Range 0-100 Default 0 |
If the number is non-zero. iRCalibration TCP Shift records the contact position to the specified position register. |
Table 20. New TCP Program Points
Position | Description |
---|---|
Circle Approach | This position must be located such that the robot can move to both Center Position 1 and Approach position 2 without collision. Also, the wrist must be able to rotate freely at this location without collision. |
Center Position 1 | Center Position 1 must be located on the side of the touch plate that is consistent with the“Plate Direction” setup value. This position should be taught centered over the touch plate circle and about one inch above the plate. |
Center Position 2 | This position is for XYZWPR recovery only. It should be taught inside the hole of the touch plate. |
Plate Position | The plate position should be taught above the plate and outside of the hole of the touch plate so the TCP will touch the plate when robot is moving in the plate direction. |
Table 21. iRCalibration TCP Shift Fit Errors
Try This |
Description |
Verify that the tool is rigid. |
Worn or damaged tooling components can cause variation in tool repeatability and can cause fit errors. |
Verify the payload setting. |
If the reference position is at an extreme position, improper payload settings can cause increased robot vibration, which affects iRCalibration TCP Shift repeatability. |
Check for a loose touch plate. * |
If the touch plate becomes loosened due to improper installation, iRCalibration TCP Shift repeatability will be affected. |
Reduce motion speed. * |
Under certain conditions, the default motion speed can cause too much vibration. For best performance, iRCalibration TCP Shift uses increased acceleration values. Try lowering the motion speed from the default 100mm/sec to 25 or 50mm/sec. |
Reduce search speed. * |
Under certain conditions, the default motion speed can cause too much vibration. For best performance, iRCalibration TCP Shift uses increased acceleration values. Try lowering the search speed from the default 10mm/sec to 5mm/sec. |
Increase the retry count. * |
iRCalibration TCP Shift has significant safeguards against getting incorrect TCP corrections. You can increase the retry count from the default of 0 to either 3 or 4 to reduce the occurrence of iRCalibration TCP Shift fit errors. |
Increase the radius tolerance. * |
The default radius tolerance of 1.0 mm may not be large enough to allow for the normal variation of some tooling. You can try increasing the radius tolerance from 1.0 mm to 1.5 mm or more as your application allows. |
Increase the fit tolerance.* |
Most iRCalibration TCP Shift errors are detected by radius tolerance, but if increasing the radius tolerance does not resolve the problem, you can increase the fit tolerance from 1.0 mm to 1.5mm or more as your application allows. |
If you are using TOS Wrist, increase the sensitivity value. * |
Normally, the default value of 10 is adequate; however, you can increase this value to either 15 or 20. |
If you are using TOS All Axis, increase the torque threshold. * |
Normally, the default value of 100 is adequate. However, if the sensitivity tolerance increases have no effect, you can increase this value to 150. |
Check for poor electrical continuity |
If the I/O method is used, and if it relies on electrical continuity, then dirty contact surfaces on either the tool or the calibration plate will result in increased fit errors. |
Table 22. Frame Schedule Detail Schedule Setup
ITEM | DESCRIPTION |
Auto Update Value: TRUE |
This item indicates whether the iRCalibration Frame Shift FIND END instruction will update the corresponding $mnuframe or not. If you set Auto Update to TRUE and run the iRCalibration Frame Shift teach pendant program, the current $mnuframe will be updated based on the offset. |
Store Offset Value: TRUE or FALSE Default: FALSE |
This item stores the cell calibration offset to a specific position register. |
in PR[0] |
If this is non-zero and "Store Offset" is TRUE, then the UFrame offset is stored in the specified position register. |
Max XYZ Offset: Min: 0.01 mm Max: 100 mm Default: 2.0 mm |
This item indicates the tolerance for any detection point shifting. If the distance between the nominal (reference) detection point and the newly detected point is larger than this value, iRCalibration Frame Shift will post a warning message. |
Report on DOUT[0]: |
If this is non-zero and iRCalibration Frame Shift detects an error then this output port will be pulsed high for 500 milliseconds. |
Fit Error Register. |
If this item is non-zero then iRCalibration Frame Shift will store the mean fit error of the detection points in this register. This value is the average deviation from nominal in the search direction of each detection point after the offset is applied |
Max Orient Change: Min: 0.01 degrees Max: 10 degrees Default: 2.0 degrees |
This item indicates the maximum tolerance for orientation changes. If the orientation of the frame exceeds this tolerance, iRCalibration Frame Shift will post a warning message. |
Mean Error Register Range: 0 — 999 Default: 0 |
If the register number is greater than 0, iRCalibration Frame Shift writes the mean error to this register. |
Max. Error Register Range: 0 — 999 Default: 0 |
If this item is greater than 0, iRCalibration Frame Shift writes the computed maximum error to this register. |
Max Dev Register: |
If this item is non-zero, iRCalibration Frame Shift will store the maximum deviation in this register. This is the distance between any of the nominal (reference) detection points and the corresponding newly detected point before the offset is applied. |
CD Pair Number: Range: 0-4 |
This item is only used in conjunction with the Coordinated
Motion option. If this item is non-zero, iRCalibration
Frame Shift will update the leader frame associated with the specified CD
Pair Number. Dynamic-UFrame must be enabled and an active follower UFrame must be set. The Dynamic-UFrame feature of Coordinated Motion can be enabled by setting the system variable $CD_PARAM.$DYN_UFRAME=TRUE. The default is FALSE. Once Dynamic-UFrame is enabled, and a CD-Pair leader group and follower group are selected a menu item appears on the Coordinated Motion Setup menu:, "Follower UFrame Number". This value determines the active dynamic UFrame for the CD pair. By default, this dynamic UFrame is relative to the Leader Frame associated with the CD Pair. Refer to the Coordinated Motion Setup and Operations manual for more information. |
Table 23. iRCalibration Frame Shift Detection Schedule Description
ITEM | DESCRIPTION |
---|---|
Sensor Type Values: TOS Wrist, I/O, TOS ALL AXES Default: TOS ALL AXES |
This item indicates the kind of sensor used for contact detection. The modes are:
|
Detection Port Values: RDI, DI, WDI, WSI, AIN |
This item indicates the desired input port type. 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 I/O as the Sensor Type. You do not need to set this up if you selected TOS Wrist or TOS All Axes as the Sensor Type. The port types are:
|
Sensor Enable Values: RDO, DOUT, WDO, or WSO Default: RDO |
This item indicates the I/O sensor enable digital
output port type. The port types are:
|
Detection Speed Units: mm/sec Range: 1.0 - 100 Default: 10 |
This item is the search speed for contact detection. 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 iRCalibration Frame Shift to retry excessively. |
Detection Distance Units: mm Range: 1 - 1000 Default: 50 |
This item is the maximum distance that the robot will move while looking for the signal. If no contact is detected within the distance, an error will be posted. |
Return Speed Units: mm/sec Range: 5 - 5000 Default: 50 |
This item is the search return speed. This speed is used for both TOS and I/O searches. |
Return to Start Default: Yes |
When this item is set to YES, the robot will move back to the position before it starts the search motion. This item applies to DETECT POINT instructions only. When this item is set to NO, the robot will move back to a distance specified by the next item (Return distance) |
Return Distance Units: mm Range: 1 - 1000 Default: 50 |
When return to start is set to FALSE, the robot will move back to the distance specified. |
Return term type Default: FINE |
This item is the termination type for return motion. |
Air Cut Speed Units: mm/sec Range: 1 - 1000 Default: 100 |
This item is the non-search motion speed. |
Learn Distance Units: mm Range: 0.5– 20.0 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 Range: 0.5 – 50.0 Default: 10.0 |
For “TOS All Axes” method only, this is the speed of the learning motion before each search. |
Sensitivity Tolerance Units: max. motor torque/sec. Range: 1 - 999 Default: 10 |
This item is the primary sensitivity tolerance of TOS Wrist and is not used for TOS All-Axes. 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 calibration 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 |
For TOS All Axes, this item is the only measure of contact detection. During the learning motion a torque level is memorized and that level plus Torque Threshold must be exceeded for contact to be determined. If false detections are being experienced then this value should be increased. For TOS Wrist, this item is the level of disturbance torque that is used as another means for contact 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 . |
Fit Tolerance Units: mm Range: 0.1 - 100 Default: 0.5 |
For Detect Circle instruction: The robot detects 4 points inside the circle and the calibration software will fit a circle to the 4 detected positions. The fit error is defined as the maximum distance from the 4 points to the circle. If the fitting error exceeds the tolerance, the calibration software will post an error. |
Radius Tolerance Units: mm Range: 0.1— 100 Default: 0.5 |
The Detect Circle instruction stores the circle's radius during mastering. At run time, if the computed circle radius differs from the stored radius value and difference exceeds the tolerance, the calibration software will post an error. |
Number or Retry Range: 0 — 9 Default: |
If the number of retry is >0, the calibration software will re-run the detect circle instruction if the current circle detection has either a fit error or a radius error. |
Contact Position Register |
If the position register number is any number other than 0, iRCalibration Frame Shift will copy the contact position to the position register. |
Table 24. Troubleshooting iRCalibration Frame Shift
Error | Cause | Remedy |
---|---|---|
Robot does not make contact with the part. |
Search starts too far from part. |
|
Search direction is not correct. |
|
|
Excessive vibration when robot is returning from the contact position back to the search start position. |
Motion speed is too high. |
|
Frame correction is inconsistent from search to search (menu or automatic). |
Search points too close. |
Make sure that search points with the same search direction are far apart from each other. |
Irregular part or part with changing dimensions. |
|
|
Frame correction is inconsistent from search to search (Menu operation). |
Convergence tolerance is too high |
Lower the convergence tolerance, be sure to allow for part deviation if applicable. |
Frame correction is inconsistent from search to search (automatic program operation) |
Search iteration is not done. |
|
Program master had one or more bad searches. |
|
|
TCP has changed since program master was done. |
|
|
Contact surfaces have changed dimensions since program mastering. |
|
Table 25. STATUS iRCALIBRATION SIGNATURE
ITEM |
DESCRIPTION |
---|---|
Group Number |
This item displays the current group number, and the user can use the F4, GROUP, key to change to another group for a controller with multiple groups. |
Signature Calibrated |
This item displays whether this robot has been calibrated or not. |
Secondary Encoder |
This item displays the status of the secondary encoder for the current group. It has two states: Inactive or Active. If the secondary encoder is enabled and active, the status will show Active. Otherwise, it shows Inactive. |
High Accuracy Mode |
This item displays the iRCaliabration Signature High Accuracy Mode. If a program is running in High Accuracy Mode, the status should show Active. Otherwise, the High Accuracy Mode shows Inactive. |