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
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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
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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
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System Overview - Assembly
Supply voltage
+24 DC
Robot controller
Field bus
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Systen Overview – Additional Sensors
Connection of 2 additional sensors
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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
Reference Pins Robot 2
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Torch calibration with stationary Sensors 1&2
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Robot Controller
Stationary Sensor 1
Stationary Sensor 2
Fixture
Moveable Sensor 3
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Fixture Calibration Robot1
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Robot Controller
Stationary Sensor 1
Stationary Sensor 2
Reference Pins Robot 1
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Fixture Calibration Robot2
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Robot Controller
Stationary Sensor 1
Stationary Sensor 2
Reference Pins Robot 2
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Fixture is transferred to another cell And Calibration process repeated
Job Transfer
Fixture and Job transfer between cells
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System Overview - Sensor
Sensor inside dimensions in mm: 120 x 120 Larger sensors available on request
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System Overview – Controller
Mounting bracket integrated
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System Overview – Operation
< OK > LEFT ACKNOWLEDGE RIGHT
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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.
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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
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Applications Calibration Modes
Selectable Dimensions
2D 3D 5D/6D
Additional Modes
Stud Welding Milling Tools Tandem Torches
Sealant Nozzles
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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
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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
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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.
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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
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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
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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
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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
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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.
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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
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Applications
6D Blade Calibration
• TCP position, orientation and cutting direction of a blade.
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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.
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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
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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
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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.
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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
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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
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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