business unit industrial solutions the quality connection presentation advintec tcp-3d calibration...

Business Unit Industrial Solutions

The Quality Connection

Presentation advintec TCP-3D Calibration System

Business Unit Industrial Solutions 223-04-10

Contents

3. Applications / Features3. Applications / Features

2. System Overview2. System Overview

1. Product portfolio Robotics1. Product portfolio Robotics

4. Technical Data4. Technical Data

5. Data Backup / Update5. Data Backup / Update

6. Additional Features 6. Additional Features

7. Customer Value 7. Customer Value

8. References8. References


Product Portfolio Robotics


System Overview - Installation

Scope of delivery LEONI:

1: TCP-3D Sensor 3: TCP-3D Controller with cable set- pedestal optional

Not included:

2. Torch Cleaner4. Robot Controller5. Robot

1

2 3

4

5


System Overview - Assembly

Supply voltage

+24 DC

Robot controller

Field bus


System Overview - Sensor

Sensor inside dimensions in mm: 120 x 120

Larger sensors available on request


System Overview – Controller

Mounting bracket integrated


System Overview – Operation

< OK >LEFT ACKNOWLEDGE RIGHT


Systen Overview – Functional Description

• advintec TCP-3D calibrates the tool electronically in 3 dimensions (X, Y, Z).

• In addition it is possible to calibrate the tool orientation in the rotational axes (Rx, Ry, Rz).

• The existing tool is referenced first, so that it is not neccessary to repeat the manual tool calibration.

• The robot Trajectory is automatically offset according to the measured deviation in the tool position.

• The tool always works in the correct position or path.


Systen Overview – Functional Description

Procedure – Use of master tool and working tool

1. Step: Working tool is saved as master tool

Commissioning

Start calibration

Start

Master tool is copied into working tool

Working tool is calibrated

Working tool is corrected

Production process with working tool


Systen Overview – What is new?

Leoni update tool

Tandem torch optionwww.imperia.mi-verlag.de

Connection of 2 additional sensors

Milling optionwww.roboter-info.de


Applications

Measurable Geometries

www.tragaskiss.com www.lotex.de www.smdv.de

Wire, Nozzle

Rotationally Symmetric Tools

Milling Tools with Flutes Cutting Tools and Blades


Applications

Calibration Modes

Selectable Dimensions

2D 3D 5D/6D

Additional Modes

Stud Welding Milling Tools Tandem TorchesSealant Nozzles


Applications

Additional Modes

Stud Welding Milling Tools Tandem TorchesSealant Nozzles

www.lotex.de www.imperia.mi-verlag.dewww.sca-schucker.dewww.emhart.eu


Applications

Activation codes for additional modes

Required information for receiving an activation code:

1. Hardware version

2. Serial number

Where do I find the hardware version and the serial number?

Serial Number

Version – HWRev. B 2.2/2.0

Version – S.No.M31/42

Main MenuSetup

Hardware Version

SetupVersion


Applications

Arc Welding

• Automated torch calibration and correction of the TCP in 2D, 3D or 5D incl. wire centricity check.

• Calibration system can be integrated directly into the torch cleaner.

• As an option, the system can take over the control of the torch cleaner via an integrated I/O-Module.


Applications

Sealing

• Automated calibration of sealant nozzles with special geometries.

• Very accurate calibration of the position and orientation of the TCP as well as checking the geometry of the nozzle.

• Detection of material build-up on the nozzle.

Image: SCA Schucker


Applications

Stud Welding

• Automated calibration of stud welding heads.

• Exact definition of the tool axis along the linear slide (5D-calbration of the TCP).

Image: Tucker


Applications

6D Gripper Calibration

• Automated 6D-calibration of the robot gripper.

• Ideal for exchangeable grippers and high-precision applications such as power train assembly.

• Compensation of temperature drift.

Image: FZ Jülich


Applications

6D Part/Gripper Calibration (Motor assembly)

• Automated 6D-calibration of the robot gripper by using a reference part with calibration pins.

• The calibration pins can also be mounted directly on the gripper.

Reference pins


Applications

Spot Welding

• Due to failures, welding guns often need to be replaced during production time.

• The average down-time per gun change in a body shop can easily amount to approximately 90 minutes.

• An early detection of gun defects is thus of principal interest.


Applications

Drilling/Milling

• Automated calibration of Milling tools and drill bits including tool breakage detection.• Ideal for use with an automatic tool changer. • Stores the dimensions of multiple tools and verifies whether the correct tool is loaded in the tool changer.

Image: Fink Plexiglas


Applications

6D Blade Calibration

• TCP position, orientation and cutting direction of a blade.


Features

• The controller can manage up to 10 different tools.

• The TCP Calibration System is fully independant of the robot brand.

• Tools with a diameter of 0.3 mm – 35 mm can be calibrated (larger tools on request)

Available Interfaces

• DeviceNet• CANopen• Interbus• Profibus• Profinet • EtherNet/IP• Ethernet TCP/IP• EtherCAT• ModbusTCP• ModbusRTU• Powerlink

• Additional interfaces on request.


Features

Calibration Times

• 2D-Calibration < 3 Seconds

Calibration of the translational axes X and Y

• 3D-Calibration < 5 Seconds

Calibration of the translational axes X, Y and Z

• 5D/6D-Calibration < 10 Seconds

Calibration of the translational axes and the orientation X, Y, Z, Rx, Ry, Rz

• 6D Gripper/Fixture Calibration >15 Seconds

depending on the application

Calibration of the translational axes and the orientation X, Y, Z, Rx, Ry, Rz


Features

• Various calibration modes can be combined for the same tool.

• Example:

A welding torch can be quickly calibrated in 2D for small deviations during the production cycle. A more precise 5D-Calibration can be carried out after a tool change.


Technical Data - Overviewadvintec TCP-3D advintec TCP-5D advintec TCP-6D

Sensor type 2 Channel Infra red 880 nm, pulsed 2kHz

2 Channel Infra red 880 nm, pulsed 2kHz

2 Channel Infra red 880 nm, pulsed 2kHz

Interface Seial or field bus (DeviceNet, Profibus, Profinet, Interbus, etc.)

Seial or field bus (DeviceNet, Profibus, Profinet, Interbus, etc.)

Seial or field bus (DeviceNet, Profibus, Profinet, Interbus, etc.)

Accuracy 0,02 mm 0,02 mm 0,02 mm

Calibration Time 3 Sec. complete 2D calibration, 6 Sec. complete 3D calibration

9 Sec. complete 5D calibration > 15 Sec. complete 6D calibration

Protection class IP67 IP67 IP67

Useable in dirty environment

Yes Yes Yes

Enclosure Aluminium Aluminium Aluminium

Dimensions 2 or 3 Translations 5 (3 Translations, 2 Rotations) 6 (3 Translations, 3 Rotations)

Automatic correction of tool data

Yes Yes Yes

Applications Arc Welding, Stud welding, Spot Welding, Laser Welding, TIG Welding, Sealing, Milling

Arc Welding, Stud welding, Spot Welding, Laser Welding, TIG Welding, Sealing, Milling

Gripper Calibration, Calibration of Fixtures, Power Train Assembly, High Precision Applications

CE-Mark Yes Yes Yes

Operating Voltage 10-34 V DC 10-34 V DC 10-34 V DC

Connectors IBS Plug, 5-pin, PE leading IBS Plug, 5-pin, PE leading IBS Plug, 5-pin, PE leading


Data Backup / Update

• With the LEONI Backup Interface the system settings can be backed up and restored.

• In the event that a controller needs to be replaced, the settings of the old unit can be transferred to the replacement unit.


Data Backup / Update

Update Tool

•With this tool it is possible to perform a software update or install custom software onto the TCP-Controller

•The system settings are retained during an update

Power


Additional Features

• Remote Configuration

The configuration can be carried out via the field bus interface. Thus all settings required for the commisioning can be made via the teach pendant of the robot.

• Initial calibration of a tool

Automated initial calibration of an unknown tool. To this end only the starting point for the initial calibration needs to be recorded.

The system then automatically calculates the tool data and transfers it to the robot controller.


Customer ValueAdvantages at a glance

• Simplified Integration in the production line due to the small footprint

• External system, the calculations are made in an external processor and the results are transferred to the robot controller

High process safety

No external PC required

Logging of calibration data

Data analysis possible at all times

• No more touching up due to tool wear or change

• 100% Quality assurance, that is higher process safety and better productivity due to the elimination of manual intervention or position related faults.

• Calibration is carried out without contact or orientation movements Short calibration times

Small footprint

• Integration in close proximity of the torch cleaner advintec TCP-Sensors are unsensitive to anti-spatter spray, as they make use of infra red technology

• Reduction of costs due to reduced scrap and rework Elimination of possible sources of error due to dependance on own exact calibration values

• Easy to use and set up


LEONI TCP Systems Worldwide

Country Site

Germany Sindelfingen Bremen Gaggenau

Sindelfingen Bremen Gaggenau

Total TCP

Belgium 5050

Others

Worldwide VW Wolfsburg VW Hannover VW Kassel VW Coaching Emden VW Mosel VW Poznan Poland VW Slovakia

Bratislava Skoda Mlada Bolislav Audi Neckarsulm VW Portugal VW Mexico

VW Wolfsburg VW Hannover VW Kassel VW Coaching Emden VW Mosel VW Poznan Poland VW Slovakia

Bratislava Skoda Mlada Bolislav Audi Neckarsulm VW Portugal VW Mexico

297297

100100

420420

Customer

Germany France

Genk Genk

LEONI TCP-Systems installed: > 867 Status 2012-05


End

Thank you for your attention

business unit industrial solutions the quality connection presentation advintec tcp-3d calibration...

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