robotics motion functions alec robertson – department dmf – confidential wonderwyler
TRANSCRIPT
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
WonderWyler
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
axis 5 0
Wyler
• Levelling method• no robot error
compensation
• low tool0 accuracy compared to nominal
• innacurate recalibration process
X
Z
Ideal tool0Actual tool0
Key
Y
foot 0°
axis 2 90°
axis 3 0
axis 4,6 0
Wyler spread
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Wyler Errors
• Existing process• error 0.9mm at tool0• error 1.5mm at TCP (200, 200, 200)
• Error sources• Placement of sensors and plates (55%)
• Tolerance of plates (35%)
• Stochastic (10%)
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
WonderWyler
• Improve process repeatability• No axis 1 mechanical components
• No mounting plates
• Highly accurate mounting cube
• Absolute measurement not relative
• Automated via RobComm/RAPID
• tool0 deviation 0.4mm
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Main Unit
Left view
Bottom view
Wyler Side
Wyler Front
Control spheres
Mounting track
Mounting track
Control spheres
Mounting track and preload spring to accomodate mounting hook (or have spring integrated into hook )
Mounting hook on robot structure
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Prototype
• Step 1• Automate via PC• Serial communication with
LevelMeter• RobComm communication
with S4C
• Step 2• Plug into S4C• RAPID automated calibration
LevelMeter 2000
Sensor A
Sensor B
RS232
RobComm
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 1
IRB140
IRB1400
50mm
IRB2400L
IRB2400
IRB6400
IRB6400R
50mm
Left or Right side of robot base
No right angle surfaces
60mm
60mm
Left or Right side of robot base
No right angle surfaces
50mm
50mm
Left side of robot base
Right angle surfaces
Machined surface
Mounting button screwed into existing threaded hole
Mounting hook
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 2 [1]
IRB1400Front of arm 2
No right angle surfaces
Back of arm 2
No right angle surfaces
50mm
50mm
50mm
50mm
IRB140
Back of arm 2
Right angle surface on right60mm
60mm IRB2400L
IRB2400
IRB4400
Machined surface
Machined surface Mounting button screwed into existing threaded hole
Mounting hook
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 2 [2]
Back of arm 2
Right angle surface on left and right50mm
50mm
IRB6400
Front of arm 2
Right angle surface on left
IRB6400R50mm
50mm
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Flange [1]
Left Face
Right Face
Interface Plate
Control spheres
Robot flange holes
Robot FlangeWonderWyler Unit
Control cylinders
Control cylinder
Control pin
Mounting hook
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Flange [2]
IRB140
IRB1400
IRB2400L
50mm 63mm 125mm 160mm
IRB2400
IRB4400
IRB6400
IRB6400R
WonderWyler unit
Interface plate
Robot flange
315mm
Voyager
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Sensors
57mm
90mm
24mm
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Overview
• Operator actions• Base, axis 1, lower arm, wrist,
flange placements
• RobComm/RAPID automation• Input angles via serial port
• Calculate axis adjustments
• Recalibrate resolvers
Base (reference)
g
Lower arm (axis 2)
Flange (axis 3–6)
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Procedure
• Connect to serial port on cabinet/robot• Run RAPID Program• Sequence
• Base/Foot
• Axis 1
• Axis 2
• Axes 3–4 on wrist
• Axes 3–6 or 5–6 on flange
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Base
• Place WonderWyler on base reference plate
• Measure reference values• Wyler Front (FR)
• Wyler Side (SR)
Wyler Front Reference Value (FR)
Wyler Side Reference Value (SR)
g
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 1 [1]
• Split kinematic coupling• Determine axis 1 adjustment
from kinematic coupling geometry (scale factor K) 1 = K·F1 - FR
Wyler Front Value (F1)
Wyler Side Value (S1)
Wyler Front Value (F1)
Axis 1 adjustment
WonderWyler kinematic coupling
Axis 2 housing
FootKinematic coupling grooves
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 1 [2]
• Retrofit REX• Fit plates to Wyler surfaces
• Machine new plates
• Plate material• Strong enough to withstand
factory abuse
• Low friction to allow sliding of WonderWyler spheres
• Integrated mounting button
WonderWyler unit
Axis 1 plate with 2 grooves
Axis 2 plate with 1 groove
Mounting button
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 2
Wyler Front Value (F2)
Wyler Side Value (S2)
• Connect to Axis 2• Run robot to CalPos2 • Measure absolute values
• Front (F2), Side (S2 )
• Axis 2 adjustment 2 = F2 - FR
CalPos2= (0,0,0,0,0,0)
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 3 - All Robots
• Connect to flange • Run robot to CalPos3 • Measure absolute value
• Front (F3)
• Axis 3 adjustment 3 = F3 - FRWyler Front Value (F3)
Wyler Side Value (S3)
CalPos3= (0,0,0,-90,0,90)
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 4 - All Robots
• Run robot to CalPos4• Measure absolute value
• Front (F4)
• Axis 4 adjustment 4 = F4 - SR
Wyler Front Value (F4)
Wyler Side Value (S4)
CalPos4= (0,0,0,-90,90,90)
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
• No need to remove tool• Connect to wrist plate• Run robot to CalPos3 • Measure absolute value
• Front (F3)
• Axis 3 adjustment 3C = mass * compliance
3W = F3 - FR
3 = 3W - 3C
Axis 3 - Large Robots
CalPos3= (0,0,0,0,0,0)
3c
no load
sag due to load
Wyler Front Value (F3)
Wyler Side Value (S3)
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 4 - Large Robots
• Measure absolute value• Front (F4)
• Axis 3 adjustment 4C = mass * compliance
4W = F4 - FR
4 = 4W - 4C Wyler Front Value (F3)
Wyler Side Value (S3)
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 5 and 6 - All Robots
• Run robot to CalPos5• Measure absolute value
• Front (F5), Side (S5)
• Axis 5, 6 adjustments 5 = F5 - FR
6 = S5 - SRWyler Front Value (F5)
Wyler Side Value (S5)
CalPos5= (0,0,0,0,0,0)
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Quality Check
Quality Check
Parallelogram Effect on Axis 3 Error
-0.20
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
-60 -55 -50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
Axis 2 (degrees)
Axi
s 3
Err
or
(Deg
rees
)
Axis 3 Error (with offset adjustment)
Axis 3 Error
Wyler Measured (24-12401)
Parallelogram Model
3=03=+13=-1
Parallel Arm Length OK!
Parallel Bar Length OK!
Predicted Reorientation OK!
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Obsolete Methods
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 1 [1]
• Use mechanical fork• Trim robot via RAPID
• Acceptable accuracy
Hollow cylinder to match 10 pin on axis 2 housing
Axis 2 housing
Base/Foot/Axis 1 housing
10 pin to fit hole in base reference plate
Calibration tool
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Axis 1 [2]
• Improve existing design• Connect axis 1 rocker arm• Measure absolute values
• Front (F1), Side (S1 )
• Axis 1 adjustment 1 = F1 - FR
arm
Wyler front
hinge Wyler Front Value (F1)
Wyler Side Value (S1)
RoboticsMotion Functions
Alec Robertson – Department DMF – Confidential
Interface Plate [3]
Control spheres
Machined grooves
Robot FlangeWonderWyler Unit
Control spheres magnetically attach (kinematic coupling) to control cylinders
No Interface Plate