tcp and fixture calibration - deutsche messe...

Business Unit Industrial Solutions

The Quality Connection

TCP and Fixture Calibration

Johannes Kemp Manager Product Development Machine Perception Business Unit Industrial Solutions E-mail: [email protected] Phone: +49-511-820 793 51 Fax: +49-511-820 793 40 Mobile: +49-163-392 90 31

mailto:[email protected]

Business Unit Industrial Solutions 2 2015-04-22

Contents

3. Applications / Features

2. System Overview

1. Product portfolio Robotics

4. Technical Data

5. Data Backup / Update

6. Additional Features

7. Customer Value

8. 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 Cleaner 4. Robot Controller 5. Robot


System Overview - Assembly

Supply voltage

+24 DC

Robot controller

Field bus


Systen Overview – Additional Sensors

Connection of 2 additional sensors


System Overview – TCP and Fixture Calibration

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Robot Controller

Sensor cable

Existing Robot Cable

Stationary Sensor 1

Stationary Sensor 2

TCP Controller

24V Power

Field Bus

Reference Pins Robot 1

Fixture

Moveable Sensor 3

Sensor cable



Torch calibration with stationary Sensors 1&2

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Robot Controller

Stationary Sensor 1

Stationary Sensor 2

Fixture

Moveable Sensor 3


Fixture Calibration Robot1

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Robot Controller

Stationary Sensor 1

Stationary Sensor 2



Fixture Calibration Robot2

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Robot Controller

Stationary Sensor 1

Stationary Sensor 2



Fixture is transferred to another cell And Calibration process repeated

Job Transfer

Fixture and Job transfer between cells


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.


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 Torches

Sealant Nozzles


Applications Additional Modes

Stud Welding Milling Tools Tandem Torches

Sealant Nozzles

www.lotex.de www.imperia.mi-verlag.de www.sca-schucker.de www.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 – HW Rev. B 2.2/2.0

Version – S.No. M31/42

Main Menu Setup

Hardware Version

Setup Version


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 • Interbus • Profibus • Profinet • EtherNet/IP • Ethernet TCP/IP

• 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


Technical Data - Overview advintec 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


Customer Value Advantages 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


Installed TCP systems worldwide (2005-2013)

37

Customers Country Plant # TCP installed since 2005 / applications

Germany China USA South Africa

Sindelfingen, Bremen, Gaggenau, Berlin, Kassel

Peking Tuscaloosa East London

483 Arc welding (MIG/MAG) Spot welding Milling, gluing Powertrain

Europe Mexico

VW Wolfsburg, VW Hanover VW Emden, Kassel, Mosel VW Poznan Polen VW Slovakei Bratislava VW Portugal, VW Mexiko Skoda Mlada Bolislav Audi Neckarsulm Porsche Weissach,

Zuffenhausen, Leipzig

304 Arc welding (MIG/MAG) Spot welding Clinching

Spain Vigo 1 Drilling

Spain

Valladolid 2 Welding (MIG)

Germany Belgium Spain

Saarlouis Genk Valencia

69 Arc welding (MIG/MAG) Spray painting

Germany France USA China South East Asia United Kingdom Switzerland Turkey

Diverse 294 Arc welding (MIG/MAG) Stud welding Gripper calibration Gluing Milling Plasma welding

Status 2014-09 LEONI TCP systems installed: ca. 1150

http://www.renault.fr/

http://www.claas.de/countries/generator/cl-pw/de/home_feature,lang=de_DE.html

http://www.magna.com/

http://www.griwe.de/index.php?L=2

http://www.uni-dortmund.de/

http://www.brose.com/ww/de/pub/home.htm

http://upload.wikimedia.org/wikipedia/de/2/26/Hagemeyer_Logo.svg


End

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tcp and fixture calibration - deutsche messe...

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